4-Cyl. Common Rail Engine (2.0l, EA189 Gen II)

Service
Workshop Manual
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II)
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Engine ID
Edition 10.2018
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00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, valve gear
17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
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21 - Turbocharging/supercharging
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23 - Mixture preparation - injection
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26 - Exhaust system
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28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D3E802D67D4

Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 3
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.5 Safety precautions
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2.6 Safety
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10 - Removing
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.3 Separating engine from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.4 Separating engine from dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.5 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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1.6 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.8 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.1 Poly V-belt drive with tensioning element and air conditioner compressor . . . . . . . . . . . . 27
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1.2 Poly V-belt drive with tensioning roller and air conditioner compressor . . . . . . . . . . . . . . . . 30
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1.3 Poly V-belt drive without air conditioning compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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1.5 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1.6 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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1.7 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - Sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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2.2 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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2.4 Assembly overview - Dual-mass flywheel and sealing flange . . . . . . . . . . . . . . . . . . . . . . 49

2.5 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.7 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4 Bearing shells - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.5 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.6 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.7 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Contents i
Sharan 2011 ➤
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.4 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.6 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.7 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.3 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.4 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.7 Renewing valve stem seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.8 Renewing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.9 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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2 Parts of lubrication system . . . . .lk.sw. a. g.e.n . . . . . . . . . . .A.G. d.o.es. n. . . . . . . . . . . . . . . . . . . . . . . . 122
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2.1 Assembly overview - oil pump, ed b sump, balance shaft module . . .u.ar.a. . . . . . . . . . . . . . . . . . .
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2.2 Removing and installing toil ho level and oil temperature sender G266 . e. o. . . . . . . . . . . . . . . . 126
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2.3 Removing and installing ss oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . .
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2.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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2.5 Removing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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2.6 Installing a new balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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2.7 Installing a previously used balancer shaft module again . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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3 Oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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3.1 Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 137
3.2 Removing and installing oil filter bracket with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 138
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3.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.4 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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3.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 147

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1.3 Assembly overview - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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1.4 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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2 Repairing cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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2.1 Removing and installing cowling together with radiator fan V7 and radiator fan on right of
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radiator V35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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2.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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2.4 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.5 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.6 Coolant pipes, coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.7 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
ii Contents
Sharan 2011 ➤
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3 Repair instructions if tank has been filled with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . 180
3.1 Step 1 (Engine was started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.2 Step 2 (Engine was not started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.3 Step 3 (There are filings in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . . . . . . . . . . . 182
3.4 Step 4 (There are no filings in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . . . . . . . . . 182
3.5 Step 5 (There are filings in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.6 Step 6 (There are no filings in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.2 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pump . . . . . . . . 185
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4.5 Emptying
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Removing and installing fuel tank . . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5 Repairing fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

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5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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5.3 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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5.4 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

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5.5 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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1.3 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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1.5 Replacing vacuum unit with position sender for charge pressure positioner G581 . . . . . . 211
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2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

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tion in
2.1 Installing hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

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2.2 Installing hose connections with corrugated pipe connection . . . . . . . . . . . . . . . . . . . . . . 218

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2.3 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

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2.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

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2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
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2.6 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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2.7 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

1 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.3 System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
2.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
2.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.3 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.4 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.1 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.2 Carrying out adaptation for injector delivery calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.3 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Contents iii
Sharan 2011 ➤
3.4 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

3.5 Installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3.6 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3.7 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 249
3.8 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3.9 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.1 Assembly overview - intake manifold with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.2 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.g.en. A. G. ..V.ol.ks. w. a.g.en. A. G
. .do. . . . . . . . . . . . . . . . . . 262
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5.1 Assembly overview - air filter . . . . . . . . .y .V . . . . . . . . . . . . . . . . . . . . . . n. o.t .gu. . . . . . . . . . . . .
olk 262
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5.2 Removing and installing air filter housing oris
ed
. . . . . . . . . . . . . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . 263
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5.3 Removing and installing air massameter ut G70 . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c. . . . . . 265
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6 Lambda probe and pressure differential sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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6.1 Removing and installing Lambda probe G39 with Lambda probe heater Z19 . . . . . . . . . . 266
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6.2 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 267
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7 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
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7.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 269
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7.2 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 270
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1 Front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
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1.1 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 272
1.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
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2 Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
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2.2 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

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2.3 Installation position and specified torque of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
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3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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3.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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3.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 286
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4 SCR system (selective catalytic reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
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4.1 Assembly overview - reduction catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
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4.2 Assembly overview - tank for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.3 Removing and installing heater element (heater cup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.4 Removing and installing injector for reduction agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 297
4.5 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
4.6 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
5 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.2 Checking changeover for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . 305
5.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 305
5.4 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
5.5 Cleaning exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
1.2 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 320
iv Contents
Sharan 2011 ➤
00 – Technical data
1 Technical data
(VRL012336; Edition 10.2018)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine data”, page 1
AG. Volkswagen AG d
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1.1 Engine number
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The first 3 characters of the
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put and varies according to engine control unit. The four-digit
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engine code can be found on the type plate, the vehicle data label
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and on the engine control unit.
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found at the joint between engine and gearbox -arrow-.
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code” and “serial number”.
The engine codes can also be found on the vehicle data sticker.
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The engine number consists of up to 9 characters (alphanumeric).
The first part (maximum 4 characters) makes up the “engine
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code”, and the second part (6 characters), the “serial number”. If

more than 999,999 engines were produced with the same code
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1.2 Engine data

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Codes CFFA CFFB CFGB CFGC CFFE

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Manufactured 07.10 07.10 07.10 02.13 05.11
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Exhaust emissions These engines comply with the threshold cop Vo
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standard.
Displace‐ l 2.0 2.0 2.0 2.0 2.0
ment
Power kW at 100/42 103/42 125/42 130/42 85/420
rpm 00 00 00 00 0
Torque Nm at 320/ 320/ 350/ 380/ 280/
rpm 1750 1750 1750 1750 1750
… 250 … 250 to to to
0 0 2500 2500 2500
Bore ∅ mm 81.0 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5 95.5
Valves per cylinder 4 4 4 4 4
Compression ratio 16.5 16.5 16.5 16.0 16.0
Fuel: acc. to DIN DIN DIN DIN DIN
EN EN EN EN EN
590 590 590 590 590
Firing or‐ 1-3-4- 1-3-4- 1-3-4- 1-3-4- 1-3-4-
der 2 2 2 2 2
Balancer shaft Yes Yes Yes Yes Yes
module
Catalytic converter Yes Yes Yes Yes Yes
1. Technical data 1
Sharan 2011 ➤
Codes CFFA CFFB CFGB CFGC CFFE

Exhaust gas recir‐ Yes Yes Yes Yes Yes
culation
Charging Yes Yes Yes Yes Yes AG. Volkswagen AG d
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Charge air cooling Yes Yes Yes Yes Yes yV
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Particulate filter Yes Yes Yes Yes Yes orised
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Selective catalytic Yes Yes Yes Yes Yesaut ra
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2 Rep. gr.00 - Technical data

Sharan 2011 ➤
2 Safety information
⇒ “2.1 Safety regulations for working on fuel supply”, page 3
⇒ “2.2 Safety measures when working on vehicles with a start/
stop system”, page 3
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, pagee4
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⇒ “2.4 Safety precautions bwhen
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⇒ “2.6 Safety precautions when working on exhaust system”,

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2.1 Safety regulations for working on fuel supply
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Risk of injury from highly pressurised fuel.
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The fuel system is pressurised. Injury from fuel spray possible.
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Before opening the fuel system:
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– Wear protective goggles.
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– Wear protective gloves.

– To release pressure, wrap a clean cloth around the connection
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and carefully loosen the connection.

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Danger of fire caused by escaping fuel

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AG.
2.2 Safety measures when working on vehicles with a start/stop system

Risk of injury from engine starting unexpectedly
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
2. Safety information 3
Sharan 2011 ➤
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2.3 Safety precautions when using testers and measuring instruments during ol ot g
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ment on the rear seat.
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Danger of scalding by steam and hot coolant.

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2.5 Safety precautions when working on the SCR system

Risk of injury due to reducing agent
The reducing agent may cause eye and skin irritations as well as
injuries to the respiratory system and poisoning.
– Wear protective goggles.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied. In
closed areas, switch on the exhaust gas extractor system.
Risk of damage caused by reducing agent

If reducing agent gets onto trim panels and body components, the
reducing agent may solidify after a while and thus damage the
surface.
– Make sure that no reducing agent gets onto the trim panels or
body components.
– If any reducing agent does get onto surfaces, remove it im‐
mediately using water and a cloth.

Sharan 2011 ➤
WARNING
Risk of skin irritation due to reducing agent:

♦ Information concerning storage and disposal ⇒ Service‐
Net → Environmental protection → Workshop disposal !
Request country specific information from importer con‐
cerning storage and disposal.
Risk due to escaping reducing agent:
♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, it is necessary to
wait until automatic return of the reducing agent is com‐
pleted ⇒ page 5 .
When removing and installing components of the SCR system,

note the following:
♦ The tank for reducing agent must be empty when working on
the SCR system. Information on when the reducing agent tank
has to be emptied can be obtained from the respective de‐
scription of work. Emptying tank for reduction agent
⇒ page 298 .
Automatic return of reducing agent
• After the ignition has been switched off, the reducing agent is
returned from the metering line leading to the reducing agent
injector - N474- back to the reducing agent tank.
• Before any work is done in thisenarea,AG. Voit
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the reducingssagent has been returned to the tank, i.e. 10 mi‐
nutes after the ignition is switched off ⇒ Electrical system;
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2.6 Safety precautions when working on exhaust system

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Risk of poisoning due to chemical substances

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Exhaust gas temperature senders may contain chemical sub‐

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stances. There is a risk of poisoning or injuries to respiratory

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system.
– Never open an exhaust gas temperature sender by cutting,
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sawing or any other means.

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Risk of injury due to hot condensate and particles in the exhaust

system.
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or
cles. There is a risk of injury to the eyes, skin and respiratory

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system, as well as poisoning.

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– Always wear protective gloves and eye protection when cut‐

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2. Safety information 5
Sharan 2011 ➤
olksw AG. V agen AG
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Risk of damage to flexible joint. ss
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♦ Do not allow the flexible joint to kink by more than 10°.
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♦ Install flexible joint so that it is not under tension.
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♦ Do not damage wire mesh on decoupling element.
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Sharan 2011 ➤
10 – Removing and installing engine

1 Removing and installing engine olkswage
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1.1 Removing and installing engine cover ss
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Removing
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The engine cover retainer on the cylinder head cover can break
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if not removed correctly. Always remove engine cover accord‐ es, in part or in w
ing to following instructions.
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– Pull engine cover panel upwards out of fasteners in areas of
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-arrows- and in sequence shown. To do this, grip as far be‐
l purpos
neath engine cover panel as possible.

Installing
nform
mercia
Caution
at
om
ion
c
in t
or
Before installing engine cover panel, check the 4 securing el‐
his
ate
ements (ball sockets) in the correct positions. Reset to correct
do
priv
position if necessary. Otherwise the engine cover panel will be
cum
for
damaged.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
– If necessary, press ball sockets of engine cover panel into
by lksw
cted agen
Prote
correct position.
AG.
– First fit engine cover panel onto mounting points, then press
into fasteners at corners.
1.2 Removing engine

Special tools and workshop equipment required
1. Removing and installing engine 7

Sharan 2011 ➤
♦ Workshop hoist - VAS 6100-
lkswage es n
o ot g
byV ua
d ran
ir se
♦ Lifting tackle - 3033- tho tee
or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
♦ Read-out the anti-theft radio code as the earth strap of the

m
a
battery has to be disconnected during the next work steps.
com
tion in
r
♦ The engine is removed forwards together with the gearbox.

te o
thi
s
iva
do
♦ All cable ties that are opened or cut through when the engine
r
rp
cum
is removed must be renewed/replaced in the same position
fo
en
g
when the engine is installed.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
WARNING
c by lksw
cted agen
Prote AG.
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route lines of any kind so that the original routing can be
restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– With ignition switched off, disconnect battery earth strap. ⇒

Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing batteries.
– Remove air filter housing together with air mass meter and
connecting pipe ⇒ page 263 .
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
8 Rep. gr.10 - Removing and installing engine

Sharan 2011 ➤
– Remove battery carrier, unscrew securing bolts -arrows- for

this.
– Remove engine cover panel ⇒ page 7 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
tion .
– Drain coolant ⇒ page 159 .
– Extract air conditioning refrigerant ⇒ Heating, air conditioning;
Rep. gr. 87 .
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 .
– Open clips -arrows- and pull coolant hoses off coolant expan‐
sion tank.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
– Pull off vacuum hoses -1- and -2- for charge air control.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Separate connectors for exhaust temperature sender 1 -

om
io
G235- -1-, for Lambda probe - G39- -3- and for exhaust
n
c
in t
r
temperature sender 3 - G495- -2- and exhaust temperature

o
his
te
sender 4 - G648- -4-.

a
do
priv
cum
or
– Cut cable ties of cables.

f
en
ng
t.
yi Co
– Guide lines out of retainers on plenum chamber bulkhead and Cop py
t. rig
on turbocharger. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Pull vacuum connection -A- off vacuum pump and detach vac‐
uum hose -arrow-.
– Remove refrigerant line securing bolt -arrow- from air condi‐

tioner compressor.
– Separate refrigerant line at air conditioner compressor and lay
it to side without kinking.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
– Disconnect quick-release
s au couplings for heat exchanger ra
c
-arrows- on plenum chamber bulkhead. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove positive wire -arrow- from starter at central electrics

and lay wire on engine.
nf
ercia
Vehicles with dual clutch gearbox

orm
m
atio
m
– Remove shift mechanism from gearbox ⇒ 6-speed dual clutch

o
n in
c
gearbox; Rep. gr. 30 .

or
thi
te
sd
iva
o
r
rp
cu
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– To release, turn catch of mechatronic connector -arrow- and

pull connector off.
Vehicles with manual gearbox
– Disconnect shift mechanism from gearbox ⇒ 6-speed manual
– Remove pipe/hose assembly or plastic line from clutch slave
cylinder ⇒ 6-speed manual gearbox; Rep. gr. 30 .
Continued for all vehicles
– Remove wiper arms and plenum chamber olkcover
swagen⇒AGElectrical
system; Rep. gr. 92 ; Windscreen n AG. Vsystem;
agewiper Removing
does
sw
olk system .
and installing windscreenbwiper
not
yV gu
a d ran
ise
– Remove plenum chamber
ut
ho
r
bulkhead ⇒ General body repairs; tee
or
Rep. gr. 50 ; Body
ss a - front; Plenum chamber bulkhead . ac
ce
e
– Remove engine control unit from retainer ⇒ page 269 .

nl
pt
du
an
itte
y li
erm
ab
– Release connector for engine wiring harness -arrow- and pull
ility
ot p
it off engine control unit.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Disconnect connectors -1- and -2- on left longitudinal member.

om
n in
or c
– Unscrew earth wire on gearbox.

thi
te
sd
iva
– Open locking element of leadthrough in plenum chamber bulk‐

o
r
rp
cu
head in direction of -arrow-.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull out upper part upwards and remove engine wiring harness
from cable guide.
– Separate all connectors between starter, gearbox and body.

Sharan 2011 ➤
– Unscrew securing bolt -arrow- on upper bracket for particulate

filter and loosen securing bolt of bracket on cylinder head one
turn.
– Open plug-in connectors -A- and -B- of fuel lines and pull fuel
lines off.
– Detach connector -1- from pressure differential

agen
AG. Volkswagsender
en AG -
does
G505- , undo bolts -arrow-. Volksw not
g
b ar y u
ed
– Remove fuel filter and opressure
ris differential sender - G505- and antee
place on engine. aut h or
ac
ss
– Disconnect connector on oil level and oil temperature sender
ce
le
un
pt
- G266- at oil sump.

an
d
itte
y li
erm
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.

ab
ility
gr. 40 .
ot p
wit
is n
h re
ole,
spec
t to the co
– Unscrew bolts -1…3- and remove pendulum support.

Vehicles with auxiliary heater
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Open clips -arrows- and pull coolant hoses off auxiliary heater
coolant.
– Loosen securing clamp -1- between particulate filter and tur‐

bocharger.
olkswagen AG
en AG. V
– Unscrew securing nuts above particulate ksfilter
wag bracket using does
not
Vol
ratchet wrench - T10384- . ed
by gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Unscrew securing nuts -arrows- of particulate filter bracket
t to the co
-A- on crankcase and remove bracket.
– Push particulate filter aside and fix it in position on plenum
rrectness of i
chamber bulkhead using suitable means.
l purpos
Note
nf
ercia
Check that all hose and line connections between engine, gear‐ orm
m
atio
box and body have been detached.

om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
– Attach lifting tackle - 3033- as follows and take up weight of

f
en
ng
t.
yi
»engine/gearbox assembly« in installation position using
Co
op py
workshop crane - VAS 6100- .
t. C rig
gh ht
pyri by
Vo
Vibration damper end:
o
by c lksw
cted agen
Prote AG.
• Item 2.
Flywheel end:
• Item 8.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Sharan 2011 ➤ aut ra
c
s
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018 s
ce
le
un
pt
an
d
itte
– Unscrew securing bolts -arrows- of assembly mounting on en‐
y li
erm
ab
gine.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Unscrew securing bolts -arrows- of assembly mounting on
mer
atio
gearbox.
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
Carefully guide »engine/gearbox assembly« when removing to

t.
yi Co
avoid damage to body. Cop py
t. rig
gh ht
pyri by
Vo
o
– Lower »engine/gearbox assembly« slightly and remove for‐ by c lksw
cted agen
wards. Prote AG.
Secure engine to engine and gearbox support - VAS 6095- to

carry out repairs ⇒ page 18 .
1.3 Separating engine from gearbox

♦ Hook - 10 - 222 A /2-

Sharan 2011 ➤
♦ Lifting tackle - T40013-
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .
– Unscrew bolts -arrows- and remove gearbox support.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Unscrew bolts -1- and -2- and remove starter from gearbox.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Vehicles with all-wheel drive:

com
tion in
r
– Unscrew bolts -arrows 2, 3- for bevel box bracket.

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
Continued for all vehicles:

– Attach lifting tackle - T40013- to gearbox and close lock.
– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /
2- to lifting tackle.
– Unscrew bolts -1, 2, 5, 6, 7, 8- from gearbox to engine con‐

nection.
– Pull gearbox off engine.
1.4 Separating engine from dual clutch gen AG. Volkswagen AG d

gearbox
a oes
ksw not
Vol gu
by a d ran
se
tho
ri tee
or
au ac
♦ Adapter - 10 - 222 A /20- ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
16
Prote AG.
Rep. gr.10 - Removing and installing engine
Sharan 2011 ➤
♦ Hook of -2024 A /1- lifting tackle - 2024 A-
Procedure
G. Volkswagen
• Engine/gearbox assembly
lksw
agenremoved and Aattached
A G do
es n to engine
bracket - T10012-
by V.
o ot g
ua
d ran
r ise t
– Remove coolant
ut
ho hoses from gear oil cooler, loosen hose
ee clips
or
-arrows-
ss for this.
a ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Attach hook of lifting tackle - 2024 A- to gearbox lifting eye and

secure with pin -arrow-.
– Attach workshop hoist - VAS 6100- to lifting tackle using hook
rrectness of i
- 10 - 222 A /20- .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Free wiring harnesses -arrows- and electrical connector -1- at

bracket.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Unscrew bolts -1- and -2- and remove starter from gearbox.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
– Unscrew remaining bolts -1, 3, 5, 6, 7, 8, 9, 10- from gearbox
c
i
or
n thi
to engine connection.
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
Bolt -3- is only accessible after removing starter.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
– Pull gearbox off engine.
AG.
1.5 Securing engine to assembly stand

Before carrying out repair work, secure engine in engine and
gearbox support - VAS 6095/1- using universal mounting - VAS
6095- .

Sharan 2011 ➤
Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
♦ Lifting tackle - 3033-
Co
Cop py
ht. rig
♦ Engine and gearbox jack - V.A.G 1383 A- rig ht
py by
co Vo
by lksw
♦ Workshop hoist - VAS 6100- cted agen
Prote AG.
♦ Engine and gearbox support - VAS 6095-

Procedure
– Unbolt gearbox.
– On vehicles with automatic gearbox, secure torque converter
against “falling out” after separating engine from gearbox.

Sharan 2011 ➤
– Attach lifting tackle - 3033- as follows and lift from engine and
gearbox jack - VAS 6100- using workshop crane - V.A.G 1383
A- .
Flywheel end: position 4.
Vibration damper end: position 8.
– Secure engine on engine and gearbox support - VAS 6095/1-
using universal mounting - VAS 6095- .
1.6 Installing engine
1.6.1 Notes on installing
Caution
. Volkswagen AG
gen AG d
When installing a new short Vol
ksw engine, it is compulsory
a oes
nto
ot gfix and
tighten the clamping ed b jaws of the injectors with the specified
y ua
ran
torque after installing
h oris
the high-pressure lines ⇒ page 237 tee.
Clamping jaws aut are only secured »hand-tight« for setting the or a
ss c
injectors while installing high-pressure lines. Non-observance
ce
e
of these notes may lead to damage to engine.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Install in reverse order of removal. When doing this, observe the

wit
, is n
following:
h re
hole
Repairing the clutch:

spec
es, in part or in w
♦ Vehicles with manual gearbox ⇒ 6-speed manual gearbox;

t to the co
Rep. gr. 30 .
♦ Vehicles with dual clutch gearbox ⇒ 6-speed dual clutch gear‐
rrectness of i
box; Rep. gr. 30 .

l purpos
– Check whether dowel sleeves for aligning engine and gearbox

are fitted in cylinder block and install if necessary.
nf
ercia
Fastening, manual gearbox to engine

orm
m
atio
m
Item Bolt Nm
o
n in
or c
11) M12x55 80
thi
te
sd
iva
M12x165 80
r
21)
rp
cu
o
m
f
en
ng
3 M10×105 40
t.
yi Co
op py
4 M10x50 40
t. C rig
gh ht
yri by
52) M12x65 80
cop Vo
by lksw
cted agen
Prote
A Dowel sleeves for centring
AG.
• 1) Bolt with M8 stud.

• 2) Bolted into gearbox from engine side.

Sharan 2011 ➤
Fastening, dual clutch gearbox to engine

Item Bolt Nm
1, 3, 10 M12x55 80
5 M12x65 80
6, 7, 8 M10x50 40
9 M12x70 80
2, 4 Starter fastening ⇒ Electrical system;
Rep. gr. 27
A Dowel sleeves for centring
– When installing »engine/gearbox assembly«, ensure sufficient
clearance to subframe and radiator.
– Adjusting assembly mountings ⇒ page 23 .
Note
♦ Specified torques for engine/gearbox assembly mountings

⇒ page 22
♦ Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 .
Vehicles with manual gearbox:

– Install hydraulic line for hydraulic clutch ⇒ 6-speed manual
– Install gearbox shift mechanism and adjust if necessary ⇒ 6-
speed manual gearbox; Rep. gr. 34 .
Vehicles with dual clutch gearbox:
– Install gearbox selector lever cable and adjust if necessary ⇒
6-speed dual clutch gearbox; Rep. gr. 34 .
wage
e ks s no
Vol t gu
d by ara
e nte
ris
Note
utho eo
ra
a c
ss
♦ After working on the particulate filter, ensure it is installed free
ce
e
nl
pt
du
of stress.
an
itte
y li
erm
ab
♦ Renew self-locking nuts, seals, gaskets and securing clamps.

ility
ot p
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
Avoid damage of flexible joint behind particulate filter. When

removing and installing:
♦ Do not allow the flexible joint to kink by more than 10°.
rrectness of i
Secure with transportation lock - T10404- .

l purpos
♦ Install flexible joint so that it is not under tension.

♦ Do not damage wire mesh on decoupling element.
nform
mercia
at
om
ion
Install particulate filter ⇒ page 274 .

c
in t
or
his
te
– Bolt drive shafts to gearbox ⇒ Running gear, axles, steering;

a
do
riv
Rep. gr. 40 ; Repairing drive shaft; Removing and installing

p
cum
or
drive shafts .
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
21
co Vo
by lksw
cted 1. Removing and installing engine
agen
Prote AG.
Sharan 2011 ➤
– Install heat shield for drive shaft (right-side) -arrows-.

Vehicles with manual gearbox:
Specified torque ⇒ 6-speed manual gearbox; Rep. gr. 34
Specified torque ⇒ 6-speed dual clutch gearbox; Rep. gr. 34
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front; Lock carrier; Removing and installing lock
carrier with add-on parts .
– Secure refrigerant lines free of stress to air conditioner com‐
pressor and to condenser ⇒ Heating, air conditioning; Rep.
gr. 87 .
wage es n
– Charge air conditioning system ⇒ Heating, air conditioning; y Volks ot g
ua
Rep. gr. 87 . ris
ed
b ran
tee
tho or
– Install battery and battery carrier ⇒ Electrical system; Rep.
au gr. ac
ss
27 ; Removing and installing battery .
ce
e
nl
pt
du
– Observe notes after connecting battery ⇒ Electrical system;
an
itte
y li
Rep. gr. 27 ; Disconnecting and reconnecting battery.
erm
ab
ility
ot p
– Fill coolant system with coolant ⇒ page 159 .
wit
, is n
h re
– Filling fuel system ⇒ page 235 .
hole
spec
– Read the event memories of all control units. Clear all fault
es, in part or in w
t to the co
entries which may have occurred during installation ⇒ Vehicle
diagnostic tester “Vehicle self-diagnosis”.
– Check headlight adjustment and correct if necessary ⇒ Main‐
rrectness of i
tenance ; Booklet 20.1 .
l purpos
Specified torques
nf
Bolted connection Specified torque
ercia
orm
Nuts and bolts M6 10 Nm
m
atio
om
n in
M7 15 Nm
or c
thi
e
M8 20 Nm
t
sd
iva
o
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rp
M10 40 Nm
cu
o
m
f
en
ng
M12 65 Nm1)
t.
yi Co
Cop py
t. rig
gh
1) Specified torque for M12 collar bolts: 75 Nm
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7 Assembly mountings
Engine mounting
A 1) = 40 Nm + turn 90° further
B 1) = 60 Nm + 90° further
C 1) = 20 Nm + 90° further
1) Renew

Sharan 2011 ➤
Gearbox mounting
1 1) = 40 Nm + 90° further
2 1) = 60 Nm + 90° further
1) Renew
Pendulum support
A 1) = 40 Nm + turn 90° further
B 1) = 60 Nm + 90° further
C 1) = 100 Nm + 90° further
1) Renew
1.8 Adjusting assembly mountings

olkswagen AG
en AG. V
olks equipment required
wag does
not
V gu
by ara
♦ Support - 10-222
or
ise A-
d
nte
th eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Adapter - 10-222 A/3-

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 2011 ➤
♦ Adapter - 10-222 A/8-
♦ Torque wrench - V.A.G 1331-

♦ Pliers for spring-type clips - VAS 6362-
Procedure
WARNING

restored.
hot components.

– Remove air filter housing ⇒ page 263 .
– Remove intake hose between air mass meter - G70- and in‐
take connecting pipe. agen AG. Volkswagen AG do
w es n
olks ot g
byV ua
ed ran
Caution
ris tee
tho or
s au ac
Risk of irreparable
s
damage to electronic components when
ce
le
disconnecting battery .
un
pt
an
d
itte
y li
♦ Comply with precautions when disconnecting battery .

erm
ab
ility
ot p
wit
is n
h re
– Disconnect earth wire -arrow- from battery with ignition switch‐

ole,
ed off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and

spec
reconnecting battery .
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Remove battery and battery tray -arrows-.

– Set up support bracket - 10-222 A- with necessary adapters
as illustrated and support engine in installation position. gen AG. Volkswagen AG d
a oes
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y Vol gu
b ara
ed nte
Note oris eo
th
au ra
c
ss
The adapters - 10 - 222 A /8- of the support bracket must be fitted
ce
e
nl
pt
with the rubber block in direction of wing -A-. Foremost attach‐
du
an
itte
ment point near bolts -arrows- of front end retaining plate.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
Note
rm
m
atio
om
n in
It is only permissible to loosen the securing bolts for the assembly
or c
mountings if the engine is supported on the support bracket -
thi
te
sd
a
10-222 A- .
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Renew engine mounting bolts -arrows- in succession (if not

already carried out) and screw in hand-tight.
– Renew gearbox mounting bolts -arrows- in succession (if not

already carried out) and screw in hand-tight.
– Loosen bolts for support arms on engine side and on gearbox
side by about two turns each.

Sharan 2011 ➤
Engine mounting
• There must be a distance -a- of at least 10 mm between engine
bracket and longitudinal member (right side).
• The side surface of the engine bracket -2- should be located
parallel to the support arm -1-.
Gearbox mounting
– Ensure that edges of support arm (on gearbox side) -1- and
gearbox mounting -2- are parallel.
• Dimension -x- must be identical on both sides of mounting.
– Tighten bolts for assembly mountings:
• Specified torques ⇒ page 22 .
The remaining installation steps are carried out in the reverse or‐
der of removal. When doing this, observe the following:
• Ensure that fuel lines are tight.
• Do not interchange supply and return lines (return line blue or
with blue markings, supply line black).
– Observe notes after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting battery .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 2011 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
n AG. Volkswagen AG
wage does
olks not
byV gu
ara
ed
Note ho
ris nte
eo
t
au ra
c
ss
If large quantities of swarf or metal particles (caused, for example,
ce
le
by partial seizure of the crankshaft or conrod bearings) are found

un
pt
an
d
in the engine oil when performing repairs, clean the oil passages
itte
y li
erm
thoroughly and renew the engine oil cooler in order to prevent
ab
ility
subsequent damage.
ot p
wit
is n
h re
ole,
⇒ “1.1 Poly V-belt drive with tensioning element and air condi‐
spec
tioner compressor”, page 27
t to the co
⇒ “1.2 Poly V-belt drive with tensioning roller and air conditioner
compressor”, page 30
rrectne
⇒ “1.3 Poly V-belt drive without air conditioning compressor”,
page 34
ss
⇒ “1.4 Removing and installing bracket for ancillaries”,
o
cial p
f
page 35
inform
mer
⇒ “1.5 Assembly overview - toothed belt drive”, page 36
atio
m
⇒ “1.6 Removing and installing engine bracket”, page 38

o
n
c
i
or
n thi
e
⇒ “1.7 Assembly overview - crankcase”, page 42

t
sd
iva
o
pr
c
1.1 Poly V-belt drive with tensioning ele‐
um
r
fo
en
ng
t.
ment and air conditioner compressor
yi Co
Cop py
t. rig
gh ht
yri
⇒ “1.1.1 Assembly overview - poly V-belt drive”, page 27 p by
co Vo
by lksw
cted agen
⇒ “1.1.2 Removing and installing poly-V belt”, page 28 Prote AG.
⇒ “1.1.3 Removing and installing poly V-belt tensioner”,

page 29
1.1.1 Assembly overview - poly V-belt drive
1. Dismantling and assembling engine 27

Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition
lkswage
10.2018 es n
o o t gu
yV
db ara
1 - Belt pulley and vibration ir se nte
ho eo
damper aut ra
ss c
❑ Offset holes make as‐
ce
le
un
pt
sembly possible in one
an
d
itte
position only
y li
erm
ab
ility
2 - 25 Nm
ot p
wit
is n
3 - Alternator
h re
ole,
spec
4 - Bracket
t to the co
❑ For ancillaries
❑ Removing and installing
⇒ page 35
rrectne
5 - 20 Nm + turn 90° further
ss
6 - Poly V-belt tensioning ele‐
o
cial p
f
ment
inform
mer
7 - Air conditioner compressor
atio
om
8 - 25 Nm
n
c
i
or
n thi
e
9 - Dowel sleeves
t
sd
iva
o
pr
c
10 - Poly V-belt
um
r
fo
en
ng
t.
❑ Mark direction of rota‐
yi Co
op
tion before removing
C py
t. rig
gh ht
yri
❑ Check for wear
p by
co Vo
by lksw
cted
❑ Do not kink
agen
Prote AG.

⇒ page 28
1.1.2 Removing and installing poly-V belt

♦ Locking pin - T10060 A-
Removing
Rep. gr. 50 ; Body - front, Assembly overview - noise insula‐
tion .
– Mark poly V-belt direction of rotation.
28 Rep. gr.13 - Crankshaft group

Sharan 2011 ➤
– Swing tensioning element in direction of arrow to remove ten‐

sion from poly V-belt.
– Align holes -arrows- and lock tensioning element in position

with locking pin - T10060 A- .
– Remove poly V-belt.
Installing
– Install in reverse order of removal.
AG. Volkswagen AG d
Note agen oes
olksw not
y V gu
d b ara
♦ Ensure, rise before installing poly V-belt, that all ancillaries
nte
(alter‐
tho eo
nator,
s au air conditioner compressor) are secured tightly. ra
c
s
ce
♦ When fitting the poly V-belt observe belt direction of rotation

le
un
pt
and that the belt is seated correctly in the belt pulleys.

an
d
itte
y li
erm
ab
ility
ot p
– Fit poly V-belt on pulleys.

wit
is n
h re
ole,
1- Crankshaft
spec
2- Tensioning element
t to the co
3- Alternator
4- Air conditioner compressor
rrectne
– Start engine and check belt running.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
1.1.3 Removing and installing poly V-belt ten‐

thi
te
sd
a
sioner
iv
o
pr
cum
r
fo
en
ng
Removing
t.
yi Co
Cop py
– Remove poly V-belt ⇒ page 28 .
t. rig
gh ht
pyri by
Vo
o
– Loosen clamp -2-, raise retaining clip -1- and remove con‐
c by lksw
cted agen
necting hose on »cold side«.
Prote AG.
– Remove cowling together with radiator fan - V7- and radiator

fan on right of radiator - V35- ⇒ page 150 .

Sharan 2011 ➤
– Remove securing bolts -arrows- from charge air pipe and sep‐
arate connector -1- from charge air pressure sender - G31- .
. Volkswagen AG
gen AG does
– Open clamp -2-, lay coolant hoseVo-3-
lkswto side and remove
a
not
charge air pipe. ed
by gu
ara
ris nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Unscrew securing bolt -2- and remove poly V-belt tensioner

o
n in
c
-1-.
or
thi
te
sd
a
Installing
iv
o
r
rp
cu
o

f
en
ng
t.
yi
following:
Co
Cop py
t. rig
♦ Specified torques ⇒ page 27
gh ht
pyri by
Vo
co lksw
by
♦ Install poly V-belt ⇒ page 28 . cted agen
Prote AG.
1.2 Poly V-belt drive with tensioning roller

and air conditioner compressor
⇒ “1.2.1 Assembly overview - poly V-belt drive”, page 30
⇒ “1.2.2 Removing and installing poly-V belt”, page 32

Sharan 2011 ➤
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
⇒ page 32
❑ Do not kink
❑ When installing, make
sure it is properly seated
on poly V-belt pulleys.
2 - Tensioning roller for poly V-
belt
⇒ page 32
❑ Coat guide surfaces
with lubricating paste;
lubricating paste ⇒
Electronic Parts Cata‐
logue .
3 - Vibration damper
❑ With poly V-belt pulley
position only
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft pul‐
ley.
4 - 10 Nm + 90°
❑ Renew AG. Volkswagen AG d
agen oes
ksw
❑ Use only genuine bolts byV
ol not
gu
ara
⇒ Parts Catalogue
ris .
e d
nte
tho eo
5 - Dowel sleeve ss au ra
c
❑ Check for correct seating in ancillary bracket.
ce
le
un
pt
an
d
itte
6 - 20 Nm + 90°
y li
rm
ab
pe
7 - 50 Nm + 90°
ility
ot
wit
, is n
8 - Idler roller
h re
hole
❑ For toothed belt

spec
es, in part or in w
t to the co
9 - 15 Nm
10 - Idler roller
rrectness of i
❑ For toothed belt

l purpos
11 - Ancillary bracket
❑ Removing and installing ⇒ page 35
nform
ercia
12 - High-pressure pump
m

a
com
tion in
13 - Bolt
r
te o
thi
s
❑ Specified torque and tightening sequence ⇒ page 36

iva
do
r
rp
cum
14 - Alternator
fo
en
ng
t.
yi
❑ Removing and installing ⇒ Rep. gr. 27
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
31
cted agen
Prote AG.
1. Dismantling and assembling engine
Sharan 2011 ➤
15 - 20 Nm
16 - Air conditioner compressor
❑ Removing and installing ⇒ Rep. gr. 87
17 - 25 Nm
18 - Dowel sleeve
❑ Check for correct seating in ancillary bracket.
19 - Bolt
Tensioning roller for poly V-belt - specified torque and tightening

sequence
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Note rise
d
nte
tho eo
au ra
♦ Renew bolt for tensioning roller. ss c
ce
le
un
pt
♦ Coat guide surfaces of tensioning roller with solid lubricating
an
d
itte
paste with a brush; solid lubricating paste ⇒ Parts Catalogue .
y li
erm
ab
ility
ot p
– Tighten bolt in 5 stages.
wit
is n
h re
ole,
Stage Bolt Specified torque/turning further angle
spec
1) -Arrow- Screw in by hand as far as stop
t to the co
• the poly V-belt is tensioned
2) -Arrow- turn until tensioning roller bolt reaches
rrectne
stop
• the poly V-belt is tensioned further
ss o
cial p
f
3) -Arrow- Turn back 90°
inform
mer
4) -Arrow- 30 Nm
atio
m
5) -Arrow- Turn 90° further

o
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
Removing
t.
yi Co
Cop py
t. rig
gh ht
yri
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐ p by
co Vo
lksw
tion .
by
cted agen
Prote AG.
Caution
Danger of destruction due to reverse running direction in the

case of a poly V-belt that has already run.
♦ Before removing the poly V-belt, use a piece of chalk or a
felt pen to mark the running direction.

Sharan 2011 ➤
– To slacken poly V-belt, unscrew tensioning screw -arrow-, re‐

move tensioning roller.
– Remove poly V-belt.
Installing
Install in reverse order of removal, observing the following.
AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise nte
♦ Renew bolt for tensioning roller. uthor eo
a ra
s c
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐ s
ce
le
nator and air conditioner compressor) are secured tightly.
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Fit poly V-belt on poly V-belt pulley:
ot
wit
, is n
1- Vibration damper
h re
hole
spec
2- Tensioning pulley
es, in part or in w
t to the co
3- Alternator
4- Air conditioner compressor
rrectness of i
– Coat guide surfaces of tensioning roller with solid lubricating
l purpos
paste with a brush; solid lubricating paste ⇒ Parts Catalogue .

– Insert tensioning roller with its pin into guide on bracket for
nform
ercia
ancillaries.
m
a
com
tio
– Tighten bolt for tensioning roller ⇒ page 32 .
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Check whether end of bolt for tension roller projects over ten‐
sioning roller running surface by dimension -a-.
• Dimension -a- = about 2.5 mm.
• This ensures that the bolt has been tightened to its end stop.
– Start engine, and check if belt runs properly.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Assembly overview - noise insulation .

Sharan 2011 ➤
1.3 Poly V-belt drive without air conditioning

compressor
⇒ “1.3.1 Assembly overview - poly V-belt drive”, page 34
⇒ “1.3.2 Removing and installing poly-V belt”, page 34
1 - Vibration damper
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft pul‐
ley.
2 - 25 Nm
3 - Alternator
5 - Poly V-belt
❑ Renew
⇒ page 34
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p

f inform
mer

atio
om
♦ Poly V-belt repair kit with assembly tools ⇒ Parts Catalogue

c
i
or
n thi
te
Procedure
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
The poly V-belt repair kit with tools contains tool -T10367- and
op Vo
by c lksw
illustrated instructions. cted agen
Prote AG.

Sharan 2011 ➤
– Remove noise insulation tray or skid plate ⇒ General body

repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview
- noise insulation .
– Loosen right wheel housing liner in front area.
– Cut through the poly V-belt.
– Proceed as described in illustrated instructions.
– Secure front part of right wheel housing liner again.
– Install noise insulation tray or skid plate ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview
- noise insulation .
1.4 Removing and installing bracket for an‐

cillaries
♦ Support - 10 - 222 A-
Removing
AG. Volkswagen AG d
agen oes
– Remove high-pressure pump
Vol ⇒ page 232 .
ksw not
gu
by ara
ed
– Remove alternator ⇒ risElectrical system; Rep. gr. 27 . nte
tho eo
s au ra
c
s
WARNING
ce
e
nl
pt
du
an
itte
y li
Do not open the air conditioner refrigerant circuit.
erm
ab
ility
ot p
wit
, is n
– Unbolt air conditioner compressor from ancillary bracket and h re

hole
attach it to lock carrier. spec

es, in part or in w
t to the co
– Unbolt idler pulleys -1- and -2-, and remove bolt of toothed belt
guard -arrow-.
– Unscrew front bolt of engine bracket.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Unscrew bolts -6 … 1- and remove bracket for ancillaries.

Installing
following:
♦ Take note of any dowel sleeves in ancillary bracket and re‐
place missing ones if necessary.
♦ Renew all bolts that must be tightened with turning further an‐
gle.
Ancillary bracket - specified torques and tightening sequence

– Insert securing bolts for ancillary bracket as follows:
♦ Bolts -1- and -2- M10 x 52.
♦ Bolts -5- and -6- M10 x 60. agen
AG. Volkswagen AG d
oes
olksw not
V gu
♦ Bolts -3- and -4- M10 x 30. d by ara
rise nte
o eo
– Tighten securing bolts for ancillary bracket inausequence
th
ra
-1 … 6- in 2 stages as follows: ss c
ce
e
nl
pt
1. Screw all bolts in to stop by hand.
du
an
itte
y li
erm
2. Tighten all bolts to 40 Nm.
ab
ility
ot p
3. Turn bolts -3- and -4- 45° further.
wit
, is n
h re
4. Turn bolts -1, 2, 5 and 6- 90° further.
hole
spec
es, in part or in w
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
t to the co
– Install high-pressure pump ⇒ page 232 .
– Install front bolt of engine bracket ⇒ Item 32 (page 38) .
rrectness of i
l purpos
1.5 Assembly overview - toothed belt drive

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing n AG. Volkswagen AG do
wage es n
❑ Check for wear yV
olks ot g
ua
d b
❑ Do not kink o
ir se
ran
tee
th or
❑ Removing, installing au ac
ss
and tensioning
ce
e
nl
⇒ page 77 .
pt
du
an
itte
y li
erm
ab
ility
❑ Renew
ot p
wit
, is n
❑ Use counterhold - 3415-
h re
to loosen and tighten.
hole
spec
❑ Do not additionally oil or
es, in part or in w
t to the co
grease thread and
shoulder.
❑ The continued turn may
rrectness of i
be made in several
steps, e.g. 90° + 45°
l purpos
3 - Crankshaft pulley
nform
ercia
4 - 20 Nm
m
at
5 - Idler roller
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or
Renew stud for idler pulley only if

f
en
ng
damaged. Specified torque for stud:

t.
yi Co
op
15 Nm.
C py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
7 - Tensioning pulley
❑ Remove engine bracket
in order to remove and
install ⇒ page 38 .
Note
Renew stud for tensioning roller only

if damaged. Specified torque for
stud: 15 Nm.

9 - Camshaft sprocket
10 - 20 Nm
11 - 100 Nm
12 - Hub
❑ Use counterhold - T10051- to loosen and tighten.
❑ To remove, use puller - T10052- .
13 - Rear toothed belt guard
14 - 20 Nm
15 - 10 Nm
❑ Renew

Sharan 2011 ➤
16 - Idler roller
❑ Renew
18 - Hub
❑ Use counterhold - T10051- to loosen and tighten.
❑ To remove, use puller - T40064- .
19 - 95 Nm
20 - Toothed belt pulley on high-pressure pump
21 - 20 Nm
22 - Coolant pump
23 - 15 Nm
AG. Volkswagen AG d
24 - Toothed belt guardlkupper
swa
gen part oes
not
o
yV gu
25 - Toothed belt ris
eguard
db lower part ara
nte
tho eo
26 - Toothed aubelt guard centre part ra
c
ss
ce
e
27 - 10 Nm
nl
pt
du
an
❑ Renew
itte
y li
erm
ab

ility
ot p
wit
❑ Renew
, is n
h re
hole
29 - Belt pulley and vibration damper

spec
es, in part or in w
❑ Offset holes make assembly possible in one position only

t to the co
30 - 5 Nm
31 - Protective plate
rrectness of i

l purpos
❑ Renew
nf
ercia
❑ Observe tightening sequence ⇒ page 38

orm
m
33 - Engine support
atio
om
n in

or c
thi
te
sd
iva
o
r
rp
cu
o
1.6 Removing and installing engine bracket

f
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
♦ Support - 10-222 A-
o
by c lksw
cted agen
Prote AG.

Sharan 2011 ➤
♦ Adapter - 10-222 A/3-
♦ Adapter - 10-222 A/8-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Pliers for spring-type clips - VAS 6362-
rrectness of i
Removing
l purpos
nform
ercia
– Remove intake line between air mass meter - G70- and tur‐
bocharger.
m
a
com
tio
– Remove fuel filter ⇒ page 195 .
n in
r
te o
thi
– Set up support bracket - 10 - 222 A- with necessary adapters
s
iva
do
as illustrated and support engine in installation position.
r
rp
cum
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
co
The adapters - 10 - 222 A /8- of the support bracket must be fitted
by lksw
cted agen
with the rubber block in direction of wing -A-. Foremost support
Prote AG.
point in area of bolts -arrows- of front end retaining plate.
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket 10-222A!
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
– Loosen bolts -B-. Remove bolts -A- and -C-.

Sharan 2011 ➤
– Unscrew bolts -B- and remove engine assembly mounting.
– Remove bolt securing coolant line -arrow-.

– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
AG. Volkswagen AG d
agen oes
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or
– Remove securing bolt of lower coolant line -arrow-.
aut
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un
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WARNING
an
d
itte
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erm
ab
When raising and lowering engine using support bracket -
ility
ot p
10-222A- , ensure that no components or hoses are damaged,
wit
is n
overstretched or torn off.
h re
ole,
spec
t to the co
Note
rrectne
The securing bolt -1- is accessible through an aperture in the
wheel housing. If necessary, raise and lower engine using spindle
s
of support bracket - 10 - 222 A- to remove or start bolts -2- and

s o
-3-.
cial p
f inform
mer
atio
om
n
c
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Cop py
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Prote AG.

Sharan 2011 ➤
– Remove securing bolts from engine bracket in sequence

-3 … 1-.
– Remove engine bracket upwards.
Installing
following:
Caution
The tightening sequence and specified torques for the engine

bracket securing bolts must always be followed. Otherwise the
engine bracket can be stressed, causing it to break.
– Insert engine bracket from above. wage

es n
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Note utho
or
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The securing bolt -1- is accessible through an aperture in the
e
nl
pt
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wheel housing. If necessary, raise and lower engine using spindle
an
itte
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of support bracket - 10 - 222 A- to remove or start bolts -2- and
erm
ab
-3-.
ility
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wit
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– First tighten new securing bolts hand-tight in sequence
hole
spec
-1 … 3-.
es, in part or in w
t to the co
Tightening sequence for engine bracket
– Retighten securing bolts in tightening sequence to prescribed
rrectness of i
specified torque ⇒ Item 32 (page 38) .
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
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t.
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– Position engine assembly mounting and first tighten bolts Cop py
. rig
-A-, then -C-. Specified torque ⇒ page 22
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co
– Bring engine bracket into contact with assembly mounting us‐
by lksw
cted agen
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ing spindle.
AG.
– Fit bolts -B- and tighten. Specified torque ⇒ page 22

Further assembly is basically a reverse of the dismantling se‐
quence. When doing this, observe the following:
♦ Ensure fuel hoses are seated correctly.
♦ Do not interchange supply and return lines (return line blue or
with blue markings, supply line black).

Sharan 2011 ➤
1.7 Assembly overview - crankcase
Caution
When installing a new short engine, it is compulsory to fix and

tighten the clamping jaws of the injectors with the specified
torque after installing the high-pressure lines ⇒ page 237 .
Clamping jaws are only secured »hand-tight« for setting the
of these notes may lead to damage to engine. agen
AG. Volkswagen AG d
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1 - Cylinder block ss c
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un
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an
sealing flange and fly‐ d
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wheel ⇒ page 44 .
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crankshaft
h re
⇒ page 69 .
hole
spec
❑ Dismantling and assem‐
es, in part or in w
t to the co
bling pistons and con‐
rods ⇒ page 61
2 - Seal
rrectness of i
❑ Renew
l purpos
3 - Oil filter bracket
nform
ercia

❑ Renew
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❑ First fit upper left and
n in
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lower right bolts and

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thi
then tighten all 4 bolts in
s
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diagonal sequence.
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5 - Bracket
n
t.
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Cop py
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6 - 10 Nm
rig
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7 - Union
lksw
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Prote AG.
❑ For thermostat
8 - 15 Nm
9 - O-ring
❑ Renew
10 - Thermostat
❑ Observe installation po‐
sition, Removing and in‐
stalling thermostat
⇒ page 154 .
❑ Checking: heat thermostat in water.
❑ Begins to open at approx. 85°C
❑ Ends at approx. 105°C
❑ Opening lift min. 7 mm
12 - Bracket
❑ For ancillaries

Sharan 2011 ➤

❑ Renew
14 - Poly V-belt tensioning element
15 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 404 A2- .
16 - 15 Nm
AG. Volkswagen AG d
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erm
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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V gu
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or eo
h
Sharan 2011 ➤ aut ra
c
s
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018 s
ce
le
un
pt
an
d
itte
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2 Removing and installing sealing
rm
ab
pe
ility
flange and flywheel
ot
wit
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h re
hole
⇒ “2.6 Renewing crankshaft sealing flange - flywheel end”,
spec
page 52 es, in part or in w
t to the co
⇒ “2.2 Renewing crankshaft oil seal - pulley end”, page 45
⇒ “2.3 Removing and installing sealing flange - pulley end”, page
rrectness of i
47
l purpos
⇒ “2.7 Removing and installing engine speed sender G28 ”, page

59
nform
ercia
Repairing the clutch:

m
a
♦ Vehicles with manual gearbox ⇒ 6-speed manual gearbox;
com
tion in
Rep. gr. 30 .
r
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thi
♦ Vehicles with dual clutch gearbox ⇒ 6-speed dual clutch gear‐
s
iva
do
r
box; Rep. gr. 30 .

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cum
fo
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2.1 Assembly overview - Sealing flange, belt pulley end

t.
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Prote AG.
❑ Renew
❑ Use counterhold - 3415-
to loosen and tighten.
grease thread and
shoulder.
❑ The continued turn may
be made in several
steps, e.g. 90° + 45°
2 - Crankshaft pulley
❑ Contact surface be‐
tween toothed belt pul‐
ley and crankshaft must
be free from oil
❑ Can only be fitted in one
position
3 - Seal
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal - belt pulley end
⇒ page 45 .
4 - Sealing flange
❑ Must seat on dowel
pins.
⇒ page 47
❑ Install with silicone seal‐
ant - D 176 404 A2- ⇒ page 47 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
nte Sharan 2011 ➤
o e
aut
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4-cylinder common rail oenginera (2.0 l, EA189 Gen II) - Edition 10.2018
ss c
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5 - Cylinder block e
nl
pt
du
an
itte
❑ Dismantling and assembling pistons and conrods ⇒ page 61
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ility
6 - Dowel pin
ot p
wit
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❑ Qty. 2
h re
hole
spec
7 - Bolt
es, in part or in w
t to the co
rrectness of i
Sealing flange at belt pulley end - Prescribed torque and tighten‐
ing sequence
l purpos
– Tighten bolts in 3 stages in the sequence shown:
nform
ercia
Stage Bolts Specified torque

m
at
1) -1 … 10- Screw in by hand as far as stop
om
ion
c
in t
2) -1 … 6- Diagonally in stages; final torque
or
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15 Nm
at
do
priv
c
3) -7 … 10- 15 Nm
um
for
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Cop py
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2.2 cted
Renewing crankshaft oil seal - pulley end
agen
Prote AG.
2. Removing and installing sealing flange and flywheel 45

Sharan 2011 ➤
equipment required
♦ Seal puller - 3203-

♦ Counter-hold tool - 3415-
♦ Assembly tool - T10053-
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
Removing
– Remove toothed belt ⇒ page 77 .
– Remove crankshaft sprocket. To do this, lock toothed belt pul‐
ley using counterhold - 3415- .
– To guide oil seal extractor - 3203- , screw central bolt by hand
into crankshaft to stop.
– Unscrew inner part of oil seal extractor 2 turns (approx. 3 mm)
out of outer part and lock with knurled screw.
– Oil threaded head of oil seal extractor.
AG. Volkswagen AG d
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olksw not
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– Using great pressure, screw oil seal extractor as far as possi‐
ce
le
un
pt
ble into seal.

an
d
itte
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erm
ab
– Loosen knurled screw and turn inner part against crankshaft

ility
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until oil seal is pulled out.

wit
is n
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Installing
ole,
spec
t to the co
Note
Do not be additionally oil or grease the oil seal sealing lip.

rrectne
– Remove oil residue from crankshaft journal using clean cloth.

ss o
cial p
f i
– Place guide sleeve - T10053/1- onto crankshaft journal.

nform
mer
– Slide oil seal over guide sleeve onto crankshaft journal.

atio
om
n
c
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or
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fo
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Press oil seal in to stop using assembly tool - T10053- and

centre bolt.
– Install crankshaft sprocket.
– Specified torque of new centre bolt ⇒ Item 2 (page 37) (2)
– How to install and tension toothed belt ⇒ page 80 .
2.3 Removing and installing sealing flange - pulley end

equipment required
AG. Volkswagen AG d
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rm
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es, in part or in w
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mercia
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com
tion in
r
te o
thi
s
iva
do
r
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t.
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Cop py
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pyri by
Vo
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by c lksw
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Prote AG.

♦ Hand drill with plastic brush

Sharan 2011 ➤
♦ Silicone sealant - D 176 404 A-

♦ Scraper
Removing
– Remove crankshaft sprocket. To do this, lock toothed belt pul‐
ley using counterhold - 3415- .
– Drain engine oil.
– Remove sump ⇒ page 126 .
– Pull off front sealing flange.
– Remove sealing flange; if necessary, loosen by applying
n AG. Vlight
olkswagen AG
blows with a rubber-headed hammer. wage does
olks no
V t gu
by ara
– Remove sealant residue from cylinder block
ris
ed with a flat scraper. nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
– Remove residual sealant from sealing flange using a plastic

itte
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rotary brush (wear eye protection).
rm
ab
pe
ility
– Clean sealing surfaces. They must be free of oil and grease.
ot
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Note
♦ Check the expiry date of the sealant.
rrectness of i
♦ The sealing flange must be installed within 5 minutes of ap‐
l purpos
plying the silicone sealant.
nform
ercia
– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

m
a
com
nozzle). tion in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
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t.
♦ The sealant bead must be no thicker than 2…3 mm. Excess
yi Co
op
sealant can find its way into the sump and block the strainer
C py
t. rig
gh
in the suction line or drip on the sealing surface of the crank‐
ht
pyri by
Vo
o
shaft seal. by c lksw
cted agen
Prote AG.
♦ Before applying sealant bead, cover sealing surface of oil seal
with a clean cloth.

Sharan 2011 ➤
– Apply silicone sealant bead as shown to the clean sealing sur‐

face of sealing flange.
– Install sealing flange immediately and tighten all bolts lightly.
Note
When fitting sealing flange with oil seal installed use guide sleeve
- T10053/1- .
– Tighten securing bolts for sealing flange to 15 Nm using alter‐

nate and diagonal sequence.
– Install crankshaft sprocket.
– Specified torque of new centre bolt ⇒ Item 2 (page 37) (2)
– Install sump ⇒ page 126 .
Note
Leave the sealant to dry for approx. 30 minutes after assembly.

Only then fill with engine oil.
Installing toothed belt and adjusting valve timing ⇒ page 80 .
2.4 Assembly overview - Dual-mass flywheel and sealing flange
lkswage es n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
AG. Volkswagen AG d
agen oes
1 - Bolt olksw not
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❑ Renew orise nte
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th
❑ 60 Nm +90° ss au ra
c
ce
le
2 - Dual-mass flywheel
un
pt
an
d
itte
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rm
ab
⇒ page 51
pe
ility
ot
wit
, is n
h re
hole
position only
spec
es, in part or in w
3 - Sender wheel
t to the co
❑ For engine speed send‐
er - G28-
rrectness of i
4 - Engine speed sender -
G28-
l purpos

⇒ page 59
nform
ercia
5 - 5 Nm
m
a
com
tio
6 - Dowel pin
n in
r
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❑ Qty. 2
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7 - Intermediate plate
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❑ Do not damage or bend

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when assembling C py
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⇒ page 50 .
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8 - Sealing flange on flywheel cted agen
Prote AG.
end
❑ With shaft seal
❑ Renewing ⇒ page 52
9 - Bolt
❑ Specified torque and
tightening sequence
⇒ page 51
Installing intermediate plate

– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel sleeves -arrows at bottom-.

AG. Volkswagen AG d
agen oes
olksw not Sharan 2011 ➤
byV gu
ara
4-cylinder
rised
common rail engine (2.0 l, EA189 nte Gen II) - Edition 10.2018
ho eo
aut ra
Sealing flange on flywheel pulley
ss end - specified torque and tight‐ c
ce
le
ening sequence
un
pt
an
d
itte
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erm
ab
ility
ot p
Stag Bolts Specified torque
wit
is n
e
h re
ole,
spec
t to the co
15 Nm
rrectness
2.5 Removing and installing dual-mass fly‐
o
cial p
f i
wheel
nform
mer
atio
om
n
c
i
or
n
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
• Gearbox is removed.
Caution
Risk of damage to dual-mass flywheel.

♦ Screw out bolts -B- not with an air wrench or power impact
wrench but by hand.
♦ When unscrewing the bolts, make sure that the bolt heads
do not touch the dual-mass flywheel.
♦ Rotate dual-mass flywheel -A- so that bolts -B- align cen‐
trally with the holes -arrows-.

Sharan 2011 ➤
– Insert counterhold - 3067- in hole in cylinder block -item B- and

loosen bolts for dual-mass flywheel.
– Unscrew bolts and remove dual-mass flywheel.
Installing
• Specified torque
⇒ “2.4 Assembly overview - Dual-mass flywheel and sealing
flange”, page 49 .
Install in reverse order of removal, observing the following. agen
AG. Volkswagen AG d
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Note ut
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s
Renew bolts for dual-mass flywheel.
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un
pt
an
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– Insert counterhold - 3067- in hole in cylinder block -item A-.
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
2.6 Renewing crankshaft sealing flange - flywheel end
t to the co
rrectness of i
equipment required
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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t.
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Cop py
t. rig
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Prote AG.

Sharan 2011 ➤

♦ Tool insert 24 mm - V.A.G 1332/11-
♦ Depth gauge
♦ 3 hexagon bolts M6 x 35 mm
♦ 2 hexagon bolts M7 x 35 mm
⇒ “2.6.1 Pressing out sealing flange with sender wheel”,
page 53
⇒ “2.6.2 Pressing in sealing flange with sender wheel”,
page 54
2.6.1 Pressing out sealing flange with sender

wheel
– Remove gearbox. ⇒ Rep. gr. 34 ; Removing and installing
gearbox
– Remove flywheel.
– Remove intermediate plate.
– Rotate crankshaft as shown to TDC No. 1 cylinder.
Note
♦ For reasons of clarity, the work is performed with the engine

removed.
Volkswagen AG
♦ The procedure is identical whether the engine is installed orswagen AG. does
removed. by
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k not
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th
au ra
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ss
– Remove engine speed sender - G28- -arrow-.
ce
le
un
pt
an
d
itte
– Unscrew sealing flange securing bolts.
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
Sealing flange and sender wheel are pressed off the crankshaft spec
es, in part or in w
together with 3 x M6 × 35 mm bolts.

t to the co
rrectness of i
l purpos
– Screw 3 M6 x 35 mm bolts into threaded holes -arrows- of

nform
ercia
sealing flange.
m
– Screw bolts (max. 180° per bolt) in sealing flange alternately

com
tio
and press it together with sender wheel off crankshaft.

n in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
2.6.2 Pressing in sealing flange with sender

wheel
Note
AG. Volkswagen AG d
agen oes
lksw not
The sealing flange with a PTFE seal is equipped with a sealing
o
♦ d byV gu
ara
lip support ring. This support ring servesoris as a fitting sleeve and
e nte
eo
must not be removed prior to installation.
aut
h
ra
ss c
♦ Do not separate or turn the sealing flange and sender wheel
ce
le
un
pt
after removal from packaging.
an
d
itte
y li
rm
♦ The sender wheel is held in its installation position on the as‐
ab
pe
ility
sembly device - T10134- by a locating pin.
ot
wit
, is n
♦ Sealing flange and oil seal form one unit and must only be
h re
hole
renewed together with the sender wheel.
spec
es, in part or in w
♦ The assembly device - T10134- is held in its position relative
t to the co
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
rrectness of i
Assembly tool - T10134-
l purpos
A - Clamping surface
nform
ercia
B - Hexagon nut
m
C - Assembly housing
a
com
tion in
D - Locating pin
r
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iva
E - Hexagon socket head bolt
do
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F - Guide pin for diesel engines (black knob)

en
ng
t.
yi Co
op
G - Guide pin for petrol engines (red knob)
C py
ht. rig
rig ht
py by
1.) Mounting seal with sender wheel on assembly tool - T10134- co Vo
by lksw
cted agen
Prote AG.
– Screw in hexagon nut -B- to just before clamping surface -A-

of threaded spindle.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on hexa‐
gon nut -B- -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.

Sharan 2011 ➤
– Remove securing clip -arrow- from new sealing flange.
Note
Do not remove the sender wheel from the sealing flange or turn
it.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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ss c
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nl
– Push sealing lip support ring -A- downwards in direction of ar‐
pt
du
an
row until it lies on flat surface.
itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Upper edge of sender wheel and front edge of sealing flange

nf
ercia
must align -arrows-.

rm
m
atio
om
n in
or c
thi
te
sd
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.

Sharan 2011 ➤
– Place sealing flange with front side on assembly tool - T10134-

so that locating pin -B- can be inserted in sender wheel hole
-A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note AG. Volkswagen AG d

agen oes
olksw not
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When installing sealing flange, ensure thatorissender
e wheel remains nte
eo
fixed in assembly device. auth
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ss c
ce
le
2.) Mounting assembly tool - T10134- with sealing flange on

un
pt
an
d
crankshaft flange
itte
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ab
• Crankshaft flange must be free of oil and grease.
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ility
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• Engine positioned at TDC No. 1 cylinder
h re
hole
spec
– Screw hexagon nut -B- to end of threaded spindle.
es, in part or in w
t to the co
– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing on sump side of crankcase rrectness of i
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sealing surface.
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tion in
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– Secure assembly tool - T10134- to crankshaft flange using

en
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t.
hexagon socket head bolts -A-.
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Note
c by lksw
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Prote AG.
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).

Sharan 2011 ➤
Volkswa
– To guide sealing flange, screw 2 M7 × s35 agmm bolts
en AG.
-A-ginto
en AG
does
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cylinder block. by Vol not
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3.) Bolting assembly tool - T10134-
tho onto crankshaft flange
ri tee
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es, in part or in w
t to the co
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft flange -A-.
rrectness of i
– Push guide pin for diesel engines (black knob) -D- into hole in
l purpos
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
nform
mercia
a
Note
com
tion in
r
te o
thi
Do not insert the guide pin for petrol engines (red knob) -F- into
s
iva
the threaded hole of crankshaft.
do
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cum
fo
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t.
– Hand-tighten both hexagon socket head bolts of assembly
yi Co
op
tool.
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– Screw hexagon nut -E- onto threaded spindle by hand until it
op Vo
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lies on assembly housing -C-.
agen
Prote AG.
4.) Pressing sender wheel onto crankshaft flange using assembly

tool - T10134-
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐

ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G
1332/11- .
Note
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
5.) Checking sender wheel installation position on crankshaft
– Screw hexagon nut -E- to end of threaded spindle.

– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.

Sharan 2011 ➤
en AG . Volkswage
– Unscrew Allen head bolts
ksw
ag-A- and remove assembly
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tool -
l
T10134- . by Vo gua d ran
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– Remove sealing
ut
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lip support ring. tee
or
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ility
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hole
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es, in part or in w
t to the co
– The sender wheel is in the correct installation position on the
crankshaft if a gap -a- = 0.5 mm exists between crankshaft
rrectness of i
flange -A- and sender wheel -B-.
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nf
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– Set vernier gauge on crankshaft flange. opyri
gh by
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c
– Measure distance -a- between crankshaft flange and sender
by lksw
cted agen
Prote
wheel.
AG.
If dimension -a- is too small:

– Re-press sender wheel ⇒ page 58 .
If dimension -a- is attained:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.
– Install engine speed sender - G28- -arrow-, and tighten se‐

curing bolt to 5 Nm.
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to
60 Nm + 90 .
6.) Re-pressing sender wheel

Sharan 2011 ➤
– Secure assembly tool - T10134- to crankshaft flange using

hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool - T10134- by hand to sealing flange.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.
– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐

ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again ⇒ page 57 .
If dimension -a- is still too small:
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
swa
gen AG
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does
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Vol gu
– Check installation position of sender wheel on crankshaft
ed
by ara
nte
again ⇒ page 57 . oris eo
th
au ra
c
ss
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nl
pt
du
an
itte
2.7 Removing and installing engine speed

y li
erm
ab
sender - G28-
ility
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Removing
hole
spec
– Remove noise insulation. ⇒ General body repairs, exterior;

es, in part or in w
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐

t to the co
tion .
– Clamp off coolant hoses from oil cooler with hose clips, up to
rrectness of i
25 mm in diameter - 3094- .
l purpos
– Loosen spring-type clips -arrows- using spring-type clip pliers

- VAS 6362- .
nform
mercia
at
Note
om
ion
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or
Collect escaping coolant with drip tray - VAS 6208- .

his
ate
do
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or
– Pull coolant hoses off oil cooler.

f
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t.
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– Remove oil filter bracket ⇒ page 137 . Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Loosen securing bolt -arrow- ( socket AF 4 mm - T10370- )

and pull out speed sender.
Installing
• Specified torque for engine speed sender - G28-
⇒ Item 5 (page 50)
• Specified torques for oil filter bracket ⇒ page 137 .
– Check coolant level, replenish coolant if necessary
⇒ page 159 .
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Sharan 2011 ➤
3 Pistons and conrods

⇒ “3.1 Assembly overview - pistons and conrods”, page 61
⇒ “3.3 Separating new conrods”, page 64
⇒ “3.5 Piston and cylinder dimensions”, page 65
⇒ “3.6 Checking piston projection at TDC”, page 65
3.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown. agen
AG. Volkswagen AG d
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❑ Checking ring gap d by V gu
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⇒ page 62 . orise nte
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❑ Checkingssring-to-groove
au ra
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clearance ⇒ page 63 .
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❑ Top and centre: Com‐
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pression rings.
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❑ Bottom: Oil scraper ring.
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2 - Piston
h re
hole
❑ With combustion cham‐

spec
es, in part or in w
ber. t to the co
❑ Mark installation posi‐
tion and cylinder num‐
ber.
rrectness of i
❑ Installation position and

l purpos
allocation of piston to
cylinder ⇒ page 64 .
nform
ercia
❑ Arrow on piston crown

points to belt pulley end.
m
at
om
❑ Install using piston ring

ion
c
clamp.
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or
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❑ If piston skirt is cracked,

a
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renew piston.
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❑ Checking piston projec‐

n
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tion at TDC t. Cop py
⇒ page 65 .
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3 - Piston pin
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❑ If difficult to remove,
heat piston to 60°C.
❑ Remove and install using drift - VW 222- .
4 - Retaining ring
5 - Connecting rod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
❑ Separate new conrod ⇒ page 64 .
6 - Bearing shell
❑ Note installation position ⇒ page 65
3. Pistons and conrods 61

Sharan 2011 ➤
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Ensure firm seating
❑ Axial clearance, wear limit: 0.37 mm
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❑ Check radial clearance owith Plastigage; wear limit:s n0.08
lks e
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❑ Do not rotate crankshaft
ir se
d
when checking radial clearance.rante
ho eo
ut
7 - Cylinder block ss a ra
c
❑ Checking cylinder bores ⇒ page 63 .
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nl
pt
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an
❑ Piston and cylinder dimensions ⇒ page 65 .
itte
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ab
8 - Conrod bearing cap
ility
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❑ Observe installation position
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❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
hole
spec
(cracking) separating the cap from the conrod.
es, in part or in w
t to the co
9 - Oil spray jet
❑ For piston cooling
rrectness of i
10 - 25 Nm
l purpos
❑ Insert without sealant.

11 - Conrod bolt, 30 Nm + 90° further
nform
ercia
❑ Renew
m
❑ Oil threads and contact surface at

om
ion
c
❑ Use old bolt for measuring radial clearance.

in t
or
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ate
do
priv
cum
for
Checking piston ring gap

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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

♦ Feeler gauge
– Push piston ring squarely from above down to approx. 15 mm
from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm (mm) (mm)
1st compression ring 0.20 … 0.40 1.00
2nd compression ring 0.20 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00

Sharan 2011 ➤
Checking ring-to-groove clearance

♦ Feeler gauge
– Clean ring groove before checking.
Piston ring New Wear limit
dimensions in mm (mm) (mm)
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
Checking cylinder bores AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
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orm

m
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om
♦ Cylinder gauge 50 …100 mm

n in
or c
thi
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– Take measurements at 3 positions in both transverse -A- and

t
sd
iva
longitudinal -B- directions, as illustrated. Difference between

o
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actual and nominal diameter max. 0.10 mm.

m
f
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t.
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Cop py
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py by
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Prote AG.

Sharan 2011 ➤
en AG. V
olkswagen AG
ag does
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ris
Note tho eo
au ra
c
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le
Cylinder bores must not be measured when the cylinder block is
un
pt
secured to engine and gearbox support - VAS 6095- , as meas‐
an
d
itte
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urements may be incorrect.
rm
ab
pe
ility
ot
wit
Checking piston
, is n
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hole
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
spec
ton pin axis with a 75 to 100 mm external micrometer.
es, in part or in w
t to the co
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension
rrectness of i
⇒ “3.2 Piston and cylinder dimensions”, page 64
l purpos
Note
nform
ercia
If piston skirt is cracked, renew piston.

m
a
com
tion in
r
te o
thi
Installation position and allocation of piston to cylinder
s
iva
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rp
c
Arrow on piston crown -arrows- points in direction of cylinder 1.
um
fo
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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
3.2 Piston and cylinder dimensions

Honing dimension Piston Ø Cylinder bore Ø
(mm) (mm)
Basic dimension 80.961) 81.01
• 1)Dimensions include coating (thickness 0.02 mm). The
coating will wear down.
3.3 Separating new conrods

On new conrods it is possible that the breaking point is not fully
separated. If the conrod bearing cap cannot be removed by hand,
proceed as follows:
– Mark cylinder allocation of conrod.

Sharan 2011 ➤
– Lightly clamp the conrod in a vice using aluminium vice

clamps, as shown in the illustration.
Note
♦ To prevent damage to the conrod, only clamp conrod in lightly.

♦ Conrod is clamped below the dashed line.
– Unscrew the two bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.
AG. Volkswagen AG d
agen oes
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3.4 Bearing shells - installation position autho eo
ra
ss c
Bearing shell -1- with oil hole -arrow- for conrod.
ce
e
nl
pt
du
an
Bearing shell -2- without oil hole for conrod bearing cap.
itte
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erm
– Position bearing shells in centre of conrod and conrod bearing ab

ility
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cap when fitting. wit

, is n
h re
Distance -a- must be identical on both sides.
hole
spec
es, in part or in w
t to the co
rrectness of i
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3.5 Piston and cylinder dimensions

nform
ercia
Piston ∅ Cylinder bore ∅

m
at
om
ion
Basic di‐ mm 80.96 81.01

c
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mension
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ate
do
priv
3.6 Checking piston projection at TDC

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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pt
du
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itte
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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by c lksw
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Prote AG.
♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-

♦ Measuring plate -VW 385/17- from universal measuring tool -
VW 385-
♦ Dial gauge - VAS 6079-
Test sequence
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in the illustration.

Sharan 2011 ➤
– Measure the projection of each piston at the two points marked

with -arrows- (at the rear side and front side of the piston seen
in the longitudinal direction of the engine).
Piston projection at TDC must be measured when new pistons or
a short engine is installed. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Note
♦ To measure the piston projection at top dead centre, turn the

engine clockwise.
♦ If different values are determined during the projection meas‐
urement, use the largest dimension for selecting the gasket.
Piston projection Identification

Holes/notches
0.91 to 1.00 mm 1
1.01 to 1.10 mm 2
1.11 to 1.20 mm 3
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3.6.1 Cylinder head gasket identification ol ot g
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♦ Part No. = arrow 1 auth or
ac
ss
♦ Holes = arrow 2
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pt
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♦ Production control code = arrow 3 (can be disregarded)
itte
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erm
ab
ility
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Note
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hole
spec
♦ Different thicknesses of cylinder head gasket are fitted de‐
es, in part or in w
pending on the piston projection. When the seal is renewed,
t to the co
ensure that the designation matches.
♦ Piston projection at TDC must be determined when installing
rrectness of i
new pistons or a short engine ⇒ page 65 .
l purpos
nf
ercia
orm
m
atio
om
3.7 Measuring radial clearance of conrods

n in
or c
thi
te
sd
a

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cu
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♦ Plastigage
f
en
ng
t.
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op
Procedure C py
t. rig
gh ht
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– Remove conrod bearing cap. Clean bearing cap and bearing
p by
co Vo
by lksw
journal. Prote
cted AG.
agen
– Place a length of Plastigage corresponding to the width of the

bearing on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm without turning
further angle and without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:

Sharan 2011 ➤
• Wear limit: 0.08 mm.

– Renew conrod bolts.
lkswage es n
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itte
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es, in part or in w
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V
ara Sharan 2011 ➤
by gu
d
ise n
4-cylinderthor common rail engine (2.0 l, EA189 Gen II) t-eeEdition
or 10.2018
au ac
ss
ce
e
nl
4 Crankshaft
pt
du
an
itte
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erm
ab
⇒ “4.1 Assembly overview - crankshaft”, page 69
ility
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⇒ “4.2 Crankshaft dimensions”, page 69
, is n
h re
hole
⇒ “4.3 Renewing needle bearing in crankshaft”, page 70
spec
es, in part or in w
4.1 Assembly overview - crankshaft
t to the co
rrectness of i
1 - Bearing shell
❑ For bearings 1, 2, 4 and
l purpos
5.
❑ Do not interchange
nform
ercia
used bearing shells

(mark).
m
at
om
ion
c
in t
or
his
e
❑ Renew
at
do
riv
❑ To measure radial clear‐

p
cum
or
ance, tighten to 65 Nm
f
en
ng
t.
yi
but not further.
Co
Cop py
t. rig
gh
3 - Bearing cap
ht
pyri by
Vo
co lksw
❑ Bearing cap 1: belt pul‐
by
cted agen
Prote
ley end.
AG.
❑ Bearing cap 3 with re‐

cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
4 - Thrust washer
❑ For bearing cap 3
❑ Note fixing arrangement
5 - Needle bearing
❑ Only vehicles with dual
clutch gearbox.
⇒ page 70
6 - Crankshaft
❑ Axial clearance new:
0.07 to 0.17 mm; wear
limit: 0.37 mm
❑ Check radial clearance with Plastigage
❑ New: 0.03 … 0.08 mm; Wear limit 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions ⇒ page 69 .
7 - Thrust washer
❑ For cylinder block, bearing 3
4.2 Crankshaft dimensions

(Dimensions in mm)
4. Crankshaft 69
Sharan 2011 ➤
Crankshaft Conrod
main journal ∅ journal ∅
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042
4.3 Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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♦ Drift - VW 207 C- aut ra
ss c
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nl
pt
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itte
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erm
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ility
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es, in part or in w
t to the co
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Condition:
• The front edges of the inner puller must be free of chips.
nf
ercia
orm
m
• Gearbox has been removed.

atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted
70
agen
Prote AG.
Rep. gr.13 - Crankshaft group
Sharan 2011 ➤
Pulling out needle roller bearing

wage es n
– Pull out needle bearingy-1- V with internal puller - VAS 251
olks ot g635-
u
-A- and counter support, ed b e.g. KUKKO 22-1 - VAS 251 621-aran
ris
-B- from crankshaft
ut
h -2-.
o tee
or
s a ac
– The internal puller must be positioned behind the needle-and-
s
ce
e
cage assembly -arrow-.
nl
pt
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ab
ility
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, is n
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
Installing
mercia
– Clean bearing seat in crankshaft and apply as thin coating of
at
om
io
grease.
n
c
in t
or
– Drive needle bearing into crankshaft to installation depth using
his
ate
do
riv
drift - VW 207 C- .
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Installation depth: dimension -a- = 2 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

renewed because it will be damaged when it is pulled out again.
4. Crankshaft 71
Sharan 2011 ➤
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head cover”, page 72
⇒ “1.2 Removing and installing cylinder head cover”, page 74
⇒ “1.2.1 Renewing seals for injectors”, page 76
⇒ “1.3 Removing, installing and tensioning toothed belt”,
page 77
⇒ “1.4 Assembly overview - cylinder head”, page 84
⇒ “1.5 Removing and installing cylinder head”, page 86
⇒ “1.6 Removing and installing vacuum pump”, page 95
⇒ “1.7 Compression test”, page 96
1.1 Assembly overview - cylinder head cov‐

er
Caution
When installing a new short engine, it is compulsory to fix and

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72 Rep. gr.15 - Cylinder head, valve gear

Sharan 2011 ➤
1 - Seal AG. Volkswagen AG d

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2 - Cylinder head cover ss a ra
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⇒ page 74
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ab
3 - O-ring
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❑ Renew
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4 - Hose
hole
spec
❑ For crankcase ventila‐
es, in part or in w
t to the co
tion.
❑ Press release buttons to
detach
rrectness of i
5 - Sealing bushing
l purpos
❑ For fuel rail

❑ Renew if damaged or
nform
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leaking
m
at
6 - Bracket
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❑ For electrical cables
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7 - Grommet
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8 - Clamping piece
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9 - 8 Nm
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10 - High-pressure accumula‐
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❑ Comply with rules for
cleanliness
⇒ page 228
❑ Do not attempt to re‐
shape high-pressure
lines.
❑ Installing high-pressure
lines ⇒ page 246 .
11 - 22 Nm
❑ Renew
13 - Fuel return line
14 - O-ring
❑ Renew
15 - Injector
❑ Comply with rules for cleanliness ⇒ page 228
16 - O-ring
❑ Renew
17 - Heat shield seal
❑ Renew
18 - Seal
❑ For injector
1. Cylinder head 73
Sharan 2011 ➤
19 - Cap
20 - Seal
❑ For sealing cover
21 - Grommet
22 - Bracket
23 - Bolt
❑ Renew gasket if damaged
Cylinder head cover - specified torque and tightening sequence

– Tighten bolts for cylinder head cover in the sequence
-1 … 6- to 9 Nm.
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1.2 Removing and installing cylinder head
h re
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cover
spec
t to the co
Removing
rrectne
– Disconnect electrical connector -2- at pressure differential
sender - G505- .
ss
– Unscrew bolt -1-, place pressure differential sender - G505-
o
cial p
f i
with bracket to one side.

nform
mer
atio
om
n
c
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Sharan 2011 ➤
– Release clips -arrows- and press upper toothed belt guard

aside to the right. n AG. Volkswagen AG do
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– Removing fuel rail ⇒ page 242 . d byV ua
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– Remove crankcase breather hose -1- from cylinder head cov‐
er; press release buttons for this.
rrectness o
cial p
f inform
mer
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n
c
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– Disconnect electrical connector -arrow- at position sender for
Co
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charge pressure positioner - G581- .
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– Remove vacuum lines from bracket on cylinder head cover.
c by lksw
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– Loosen and unscrew bolts for cylinder head cover in the se‐
quence -6 to 1-.
– Remove cylinder head cover.
1. Cylinder head 75
Sharan 2011 ➤
Installing
Note
♦ Renew gasket for cylinder head cover and bolts for cylinder
head cover if damaged or leaking.
♦ Renew grommets and seals for injectors if damaged or leak‐
ing.
– Tighten bolts for cylinder head cover ⇒ page 74 .
– Ensure that cylinder head cover is correctly clipped to toothed

belt guard -arrows-.
Note
For reasons of clarity, illustration shows installation position with

camshaft sprocket removed.
– Check clearance between hub and toothed belt guard.

– Install coolant return line.
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– Install intake pipe ⇒ page 205 . Volksw
oes
not
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– Installing fuel rail and injectors ⇒ page 242 . orise nte
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th
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– Install pressure differential sender - G505- . ss a c
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1.2.1 Renewing seals for injectors
h re
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spec
t to the co
♦ Follower - 3390-
rrectness o
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f inform
mer
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Sharan 2011 ➤
Procedure
– Remove cylinder head cover ⇒ page 74 .
– Press out seal for injector using carrier - 3390- and short ex‐
tension -1- upwards from below.
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– Press in news auseal
t
for injector using carrier - 3390- and short ra
c
extension -1-
s from top to stop.
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– Install cylinder head cover ⇒ page 74 .
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1.3 Removing, installing and tensioning toothed belt

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or
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1. Cylinder head 77
Sharan 2011 ➤ AG. Volkswagen AG d
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4-cylinder common rail engine (2.0 l, EA189 Gen II) -VoEdition
lksw 10.2018 oes
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Special tools and workshop tho
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equipment required au ra
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♦ Pin - 3359-
♦ Crankshaft stop - T10050-
♦ Counter-hold tool - T10172-
♦ Angled screwdriver - T10264-
♦ Locking tool - T10265-
Not illustrated:
1.3.1 Removing
Note
The toothed belt may only be adjusted on cold engines, as the

indicator position on the tensioning element varies depending on
the engine temperature.


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– Pull connector off radiator
ss a
outlet coolant temperature sender c
- G83- , open clips -arrows- and remove toothed belt guard.
ce
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nl
pt
du
an
– Remove front right wheel housing liner ⇒ General body re‐
itte
y li
erm
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
ab
ility
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wit
, is n
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– Remove vibration damper ⇒ Item 29 (page 38) .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove lower and centre toothed belt guard -arrows- and un‐
screw securing nut of coolant pipe -1-.
nform
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– Position crankshaft at TDC and lock crankshaft toothed belt

pulley with crankshaft stop - T10050- . To do this, push crank‐
shaft stop into teeth of belt pulley from face side. Depending
on the production version, either the toothed segment or the
arrow on the camshaft toothed belt pulley must be at »12
o'clock«.
Note
The markings on the crankshaft pulley -2- and the crankshaft stop
- T10050- -1- must align. At the same time, the pin of the crank‐
shaft stop - T10050- must engage in the drilling in the sealing
flange.
– Mark direction of rotation of toothed belt.
– Loosen securing bolts -1- for camshaft toothed belt pulley.
1. Cylinder head 79
Sharan 2011 ➤
– Loosen securing bolt of coolant pipe -1- and then securing

bolts of toothed belt pulley for high-pressure pump -2-.
– Loosen tensioning roller securing nut -1-.
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– Turn eccentric of tensioning roller anti-clockwise -arrow- using
itte
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socket - T10264- , until the tensioning roller can be locked with
ab
ility
locking tool - T10265- .
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es, in part or in w
t to the co
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nform
ercia
– Now turn tensioning roller eccentric clockwise -arrow- onto

m
at
stop and tighten securing nut -1- hand-tight.
om
ion
c
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– Remove toothed belt first from idler pulley and then from re‐
or
his
e
maining pulleys.
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1.3.2 Installing
Note
♦ The toothed belt may only be adjusted on cold engines, as the

indicator position on the tensioning element varies depending
on the engine temperature.
♦ If the tensioning roller is to be renewed, the engine bracket
must be removed ⇒ page 38 .
♦ Renew securing bolt for camshaft toothed belt pulley.
• Tensioning roller must be locked with locking tool - T10265-

and secured to right stop.
• Crankshaft is locked using crankshaft stop - T10050- .

Sharan 2011 ➤
Note
If necessary, turn camshaft hub with counterhold - T10172- and

adapters - T10172/4- until camshaft can be secured in position.
To do this, hand-tighten at least one securing bolt -1-.
– Lock camshaft hub with locking pin - 3359- . To do this, slide

locking pin through outer free elongated hole into hole in cyl‐
inder head.
– Loosen bolts which had been tightened only hand-tight.
Note
If necessary, turn hub of high-pressure pump at bolt heads with

screwdriver until it can be secured in position.
Positioning hub of high-pressure pump
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– Lock hub of high-pressure pump with locking pin - 3359- . To

t to the co
do this, slide locking pin into adjustment hole outside toothed

belt pulley.
rrectness of i
– Turn camshaft toothed belt pulley and toothed belt pulley of

high-pressure pump in their elongated holes clockwise to stop.
l purpos
– Fit toothed belt to crankshaft pulley, tensioning roller, cam‐

shaft pulley, toothed belt pulley of coolant pump and toothed
nform
ercia
belt pulley of high-pressure pump.

m
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– Finally, fit toothed belt to idler pulley.

ion in
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– Loosen tensioning roller securing nut and pull out locking tool
thi
s
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- T10265- .
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1. Cylinder head 81
Sharan 2011 ➤
Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
– Screw eccentric of tensioning roller clockwise carefully using

angled screwdriver - T10264- . Indicator -2- must be roughly
past the centre of the gap in the base plate (corrects itself dur‐
ing pretensioning).
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten securing nut
for tensioning roller as follows: 20 Nm and 45° further.
– Apply counterhold - T10172-geas Ashown.

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– In this position,
au first tighten securing bolts -1- of camshaft pul‐ r ac
th o
ley and of toothed
ss belt pulley for high pressure pump by hand
ce
and then tighten to 20 Nm.

le
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– Remove locking pins - 3359- and crankshaft stop - T10050- .

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– Turn crankshaft at least 2 rotations in engine direction of ro‐

ot
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tation and set again to TDC no. 1 cylinder.

, is n
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hole
– Fit crankshaft stop - T10050- again to crankshaft belt pulley.

spec
es, in part or in w
t to the co
– Now turn crankshaft in engine direction of rotation until pin of

crankshaft stop -arrow- engages in sealing flange from rota‐
rrectness of i
tional movement.
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Sharan 2011 ➤
AG. Volkswagen AG d
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During the following checking procedure, only the horicamshaft
s and nte
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crankshaft must be secured in position. It is very
s aut difficult to find ra
c
the securing position of the high-pressure pump
s hub again. A mi‐
ce
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nor deviation -arrow-, though, does not influence engine opera‐
un
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an
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– Check whether:
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♦ Camshaft hub can be locked with locking pin - 3359- .
hole
spec
♦ Tensioning roller indicator is centred or maximum 5 mm to
es, in part or in w
t to the co
right of base plate notch.
If camshaft hub cannot be locked:
rrectness of i
– Pull crankshaft stop - T10050- back until pin uncovers hole.
l purpos
– Turn crankshaft in opposite direction of engine rotation slightly

past TDC.
nform
ercia
– Now turn crankshaft slowly in direction of engine rotation until

camshaft hub can be secured in position.
m
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– After locking, loosen securing nuts of camshaft pulley.
n in
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If pin of crankshaft stop - T10050- is standing on left next to hole:
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– Turn crankshaft in engine direction of rotation until crankshaft
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stop pin engages in sealing flange whilst turning. t. Cop py
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– Tighten securing bolts of camshaft toothed belt pulley by hand yri
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first and then tighten to 20 Nm.
lksw
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If pin of crankshaft stop - T10050- is standing on right next to hole:
– Slightly turn crankshaft in opposite direction of engine rotation.
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin engages in sealing flange whilst turning.
– Tighten securing bolts of camshaft toothed belt pulley by hand
first and then tighten to 20 Nm.
Continuation
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Turn crankshaft at least 2 rotations in engine direction of ro‐
tation and set again to TDC no. 1 cylinder.
– Repeat check.
– If camshaft hub can be secured in position, tighten securing
bolts as follows:
1. Cylinder head 83
Sharan 2011 ➤
♦ Camshaft sprocket: 45° further. Counterhold with counterhold

- T10172- and adapters - T10172/4- .
– Install centre and lower parts of toothed belt guard.
n AG. Volkswagen A ge G do
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– Install belt pulley vibration
by
Voldamper: specified torque 10oNm
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– Install poly V-belt
ss
au ⇒ page 27 . ra
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– Install upper toothed belt guard.

nl
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Further assembly is basically a reverse of the dismantling se‐
erm
ab
quence. When doing this, observe the following:
ility
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hole
♦ Do not interchange fuel supply and return lines (return line is
spec
blue or with blue markings and supply line is white).
es, in part or in w
t to the co
– Install wheel housing liner.
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
rrectness of i
gr. 50 ; Body - front; Assembly overview - noise insulation .
l purpos
1.4 Assembly overview - cylinder head
nf
ercia
orm
m
atio
1 - Cylinder head gasket
om
n in
c
❑ Renew
or
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❑ Cylinder head gasket

t
sd
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identification
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rp
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⇒ page 86
f
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ng
t.
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❑ Renew coolant and en‐ Cop py
gine oil after replacing.
t. rig
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2 - 10 Nm
c by lksw
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Prote AG.
❑ Insert with locking fluid,
locking fluid ⇒ Electron‐
ic parts catalogue .
3 - Hall sender - G40-
❑ For camshaft position.
4 - Cylinder head
⇒ page 86
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
❑ Check for distortion
⇒ page 86 .
❑ Must not be reworked.
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head on cylinder
block are fitted.
❑ Renew coolant and en‐
gine oil after replacing.
5 - Washer
6 - Cylinder head bolt
❑ Renew
❑ Sequence when loosening ⇒ page 85 .

Sharan 2011 ➤
7 - Oil pressure switch - F1- , 20 Nm
❑ Switch pressure 0.3 to 0.6 bar
❑ Removing and installing ⇒ pagesw141 AG. Volkswagen AG d
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❑ Checking ⇒ page 142 ed by V gu
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8 - Seal autho eo
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❑ Renew
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9 - 20 Nm
an
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10 - Engine lifting eye
ility
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11 - Seal
is n
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❑ Renew
spec
12 - 20 Nm
t to the co
13 - Seal
❑ Renew
rrectne
14 - Vacuum pump
s
s o
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15 - 10 Nm
nform
mer
16 - Union
atio
om
❑ For coolant hoses
n
c
i
or
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❑ With coolant temperature sender - G62-
te
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17 - 9 Nm
um
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18 - Seal
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❑ Renew
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19 - 20 Nm
c by lksw
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Prote AG.
20 - Engine lifting eye
Observe sequence when loosening cylinder head bolts

– Loosen cylinder head bolts in the sequence -1 … 10-.
1. Cylinder head 85
Sharan 2011 ➤
Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure cylinder head
for distortion at several points.
• Max. permissible distortion: 0.1 mm
Note
Cylinder heads for TDI engines must not be reworked. AG. Volkswagen AG d
agen oes
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Cylinder head gasket identification s
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1- Part number
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2- Holes
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3- Ignore
, is n
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spec
es, in part or in w
Note
t to the co
Different thicknesses of cylinder head gasket are fitted depending
on the piston projection. If only cylinder head gasket is removed,
rrectness of i
install a new cylinder head gasket with same identification.
l purpos
nform
mercia
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com
tion in
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Cylinder head - specified torque and sequence
fo
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Note
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Renew cylinder head bolts.
Prote AG.

Stage Bolts Specified torque/turning further angle
1) -1 … 10- 30 Nm
2) -1 … 10- 50 Nm
3) -1 … 10- Turn 90° further
4) -1 … 10- Turn 90° further
1.5 Removing and installing cylinder head

Sharan 2011 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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♦ Guide pin - 3070-
hor eo
aut ra
s c
♦ Diesel injection
s pump locking pin - 3359-
ce
le
un
pt

an
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itte
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ab

ility
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♦ Puller - T10052-
wit
is n
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ole,
♦ Bit XZN 10 - T10385-

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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agen 1. Cylinder head
Sharan 2011 ➤
AG. Volkswagen AG d
agen oes
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♦ Torque wrench - V.A.G 1332- C py
ht. rig
rig ht
♦ Drip tray for workshop hoist - VAS 6208-
py by
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Prote AG.
Note
♦ Read-out the anti-theft radio code as the earth strap of the

battery has to be disconnected during the next work steps.
♦ All cable ties which are opened or cut through when cylinder
head is removed must be renewed/replaced in the same po‐
sition when the cylinder head is installed.

Sharan 2011 ➤
WARNING

restored.
hot components.
1.5.1 Removing
– With ignition switched off, disconnect battery earth strap. ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing batteries.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Remove cowling together with eradiator
n AG. Volkfan
swag-eV7-
n AG and radiator
fan on right of radiator - V35-
olkswag⇒ page 150 . does
not
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– Remove connecting ris hose on »cold side«
e nte
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⇒ Item 4 (pageau219) from charge air cooler. eo
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– Pull connector off throttle valve module - J338- -2-.

itte
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– Remove bolt from oil dipstick attachment -4-.

ility
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– Disconnect vacuum line from vacuum pump.

h re
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spec
t to the co
rrectness o
cial p
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– Unscrew bolts -2, 5- and -arrows-. C py
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– Free electrical wiring and hoses on left air pipe using removal cop Vo
by lksw
lever - 80 - 200- . cted agen
Prote AG.
– Release hose clip -3- and remove left air pipe.
1. Cylinder head 89
Sharan 2011 ➤
– Unscrew bolts -arrows- and remove pulsation damper -2-.

Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
– Disconnect electrical connector -4- on coolant temperature
sender - G62- .
– Pull coolant hoses off connection. To do this, loosen hose clips

-1- and -2-.
– Disconnect electrical connector -1- on oil pressure switch -

F1- .
– Remove bolt -arrow-.
– Pull off vacuum hose -2-.
AG. Volkswagen AG d
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– Disconnect connectors for exhaust gas temperature sender 1

ot p
- G235- -1-.
wit
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hole
– Free electrical lines on turbocharger.

spec
es, in part or in w
– Remove radiator cowl together with radiator fans

t to the co
⇒ page 150 .
rrectness of i
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Cop py
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Prote AG.

Sharan 2011 ➤
– Unscrew securing bolts -arrows- from charge air pipe and dis‐
connect connector from charge air pressure sender - G31-
-1-. AG. Volkswagen
agen AG do
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– Open clamp -2-, lay coolant hose -3- to side and remove
nform
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charge air pipe.

m
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Caution
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Ensure that decoupling element of connecting pipe is not bent

a
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and thus stretched. There is a danger of cracking.

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– Remove connecting pipes for exhaust gas recirculation -A-

using bit XZN 10 - T10385- .
1. Cylinder head 91
Sharan 2011 ➤
– Unscrew securing nuts -arrows- of bracket for particulate filter

-A- at crankcase.
– Unscrew union nut -2- and unscrew bolt -3-.
– Unscrew bolt -arrow- from rear toothed belt guard.

– Release connecting clamp between turbocharger and diesel
particulate filter.
AG. Volkswagen AG d
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– Unscrew securing bolt from bracket on cylinder head -arrow-

, is n
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and push diesel particulate filter to side.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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Cop py
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AG. Volkswagen AG d
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Volksw Sharan no2011
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4-cylinder common rail engine
rised b
(2.0 l, EA189 Gen II) - Edition 10.2018
ara
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– Separate connector for Hall sender - G40- -arrow-.
ss c
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– Take toothed belt off camshaft ⇒ page 77 .
pt
du
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– Remove camshaft toothed belt pulley and pull off camshaft
erm
ab
hub using puller - T10052- .
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– Unscrew securing nut of toothed belt tensioning roller.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Separate connector for Hall sender - G40- -arrow-.
nf
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– Maintain sequence -1 … 10- when loosening cylinder head

bolts.
Note
♦ A second mechanic is required for the removal of the cylinder

head.
♦ The toothed belt tensioning roller is pulled off the stud when
the cylinder head is lifted out.
♦ The oil return line of the turbocharger is pulled out of the sup‐
port when the cylinder head is lifted out.
– First lift cylinder head on gearbox side and guide it out of

toothed belt guard. Prevent toothed belt tensioning roller from
falling down.
– Place cylinder head down taking care not to bend oil return
line. If necessary, place a piece of wood under exhaust mani‐
fold.
1.5.2 Installing
Install in reverse order of removal, observing the following:
1. Cylinder head 93
Sharan 2011 ➤
Note
♦ Do not use sandpaper, grinding wheels, abrasive or scour

pads or any other sanding or abrasive media.
♦ Sealing surface (see photo) must not project.
♦ Discolouration (dark spots, see photo) need not be removed.
♦ When removing the sealant residue, make sure no loose par‐
ticles get into the open channels of the engine.
♦ Ensure that all adjacent workspaces are clean, and that none
of the above mentioned sanding or abrasive media are used.
♦ Using unauthorised sanding or abrasive media may
olks
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age to es n
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secondary damage such as, for example, damage
db
y V to the tur‐ ua
ran
bocharger or the conrod bearings. o rise tee
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au ac
ss
– Do not use any other means rather than the contour blade set
ce
le
un
- VAS 852 005- or a commercially available CERAN surface
pt
an
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scraper to remove the sealant residue from the cylinder head

itte
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and cylinder block.
ab
pe
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• The sealing surfaces must not be damaged.
wit
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• There must be no oil or coolant in the bolt pockets.
hole
spec
es, in part or in w
• Do not remove new cylinder head gasket from packaging until
t to the co
it is ready to be fitted.
• If a new cylinder head is installed, contact surfaces between
rrectness of i
roller rocker fingers and running surface of cam must be oiled.
l purpos
• Handle the cylinder head gasket very carefully to prevent

damage to the silicone coating or the indented area of the
gasket.
nform
ercia
• Turn the crankshaft carefully at least 2 rotations to ensure that

m
a
none of the valves make contact when the starter is operated.
com
tion in
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• When the cylinder head or cylinder head gasket is renewed,

te o
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the entire coolant and the engine oil must be changed.

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– Remove any loose remains using a lint-free cloth.

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– Before fitting cylinder head, remove crankshaft stop - . Cop py
T10050- , and turn crankshaft in opposite direction of engine
ht rig
rig ht
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rotation until all pistons are nearly uniformly below TDC. copy Vo
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– Cylinder head gasket must lie with identification facing up‐
AG.
wards.
– To centre, screw guide pins - 3070- into outer threaded holes

on intake side.
Note
Tensioning roller must be pushed onto studs when fitting cylinder

head.
– Fit cylinder head, start 8 cylinder head bolts and hand-tighten.

– Remove guide pins through bolt holes using removal tool from
3070 and install cylinder head bolts.

Sharan 2011 ➤
– Tighten cylinder head in 4 stages in sequence shown as fol‐

lows:
1- Tighten initially with torque wrench:
Stage I = 30 Nm
Step II = 50 Nm
2- Turn further with rigid spanner:
Stage III = 90°
Stage IV = 90°
– Secure toothed belt rear guard to cylinder head.
– Install hub and camshaft pulley.
– Lock camshaft and high-pressure pump with diesel injection
pump locking pin - 3359-
– Now rotate crankshaft in direction of rotation to TDC and lock

crankshaft using crankshaft stop - T10050- .
– Fit toothed belt ⇒ page 80 .
Continue installation in reverse order of removal. When doing this,
observe the following:
AG. Volkswagen AG d
agen oes
– Install cylinder head cover ⇒ page 74 . olksw not
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– Install poly V-belt ⇒ page 27 . horis nte
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– Add coolant ⇒ page 159 . ss c
ce
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pt
– Carry out road test and read event memory.
an
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1.6 Removing and installing vacuum pump
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spec
DANGER!
t to the co
The vacuum pump may, under no circumstances, be disman‐
tled as the vacuum part could otherwise malfunction. This
would result in failure of the brake servo.
rrectness
Removing
o
cial p
f in
form
mer
atio
– Pull vacuum line -1- off vacuum pump -2-.
om
n
c
– Unscrew securing bolts of charge air pipe ⇒ page 218 .

or
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– Then push charge air pipe down slightly to gain access to the
iv
o
pr
rear bolt of the vacuum pump.

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Cop py
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1. Cylinder head 95
Sharan 2011 ➤
– Unscrew securing bolts -arrows-.

– Remove vacuum pump -2- from cylinder
en AG. V
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Installation is carried
tho out in the reverse order. When installing,tee o
note the following:
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♦ Ensure that vacuum pump coupling seats properly in cam‐
ot
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shaft.
h re
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spec
♦ The seal must be renewed.
es, in part or in w
t to the co
– Install vacuum pump and tighten securing bolts to 10 Nm.
– Connect vacuum line -1- from brake servo to vacuum pump.
rrectness of i
l purpos
1.7 Compression test

nform
ercia
♦ Jointed spanner - 3220-

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tion in
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Prote AG.
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

1763/8-

Prerequisites for check
• Engine oil temperature min. 30°C
Test sequence
– Pull connectors off injectors.
– Remove glow plug from relevant cylinder using U/J extension
and 10 mm socket - 3220- ⇒ page 318 .
– Screw in adapter - V.A.G 1763/8- in place of glow plug.
– Check compression using compression tester - V.A.G 1763- .

Sharan 2011 ➤
Note
Using the compression tester ⇒ Operating manual.
– Turn over engine until tester shows no further pressure in‐

crease.
Compression pressures:
New: 25…31 bar
Wear limit: 19 bar
Maximum permissible difference between oall
lkscylinders:
wage 5 bar es n
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V
by ua
– Install glow plug using U/J extension
ris
ed and socket, 10 mm - ran
tee
3220- ⇒ page 318 . ut
ho
or
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ss
– Read event memory of engine control unit.
ce
e
nl
pt
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Note
ility
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Faults will have been stored because the connectors for injectors
h re
have been disconnected. Therefore, read event memory and de‐
hole
spec
lete if necessary.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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Cop py
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1. Cylinder head 97
Sharan 2011 ➤
AG. Volkswagen AG d
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2 Valve gear
oes
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Caution s au ra
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Avoid damage to valves and piston crowns after working on
an
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valve gear.
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♦ Because hydraulic compensation elements have to settle,
ot p
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engine must not be started for approx. 30 minutes after
is n
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installing camshafts.
ole,
spec
♦ Turn the crankshaft carefully at least 2 rotations to ensure
t to the co
that none of the valves make contact when the starter is
operated.
rrectnes
Note
s o
cial p
f inform
Cylinder heads with cracks between the valve seats may be used
mer
without reducing engine life, provided the cracks are small and no
atio
m
more than 0.5 mm wide.

o
n
c
i
or
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sd
⇒ “2.1 Assembly overview - valve gear”, page 98
iva
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⇒ “2.2 Removing and installing camshafts”, page 101

fo
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⇒ “2.5 Removing and installing camshaft oil seal”, page 109 Cop py
t. rig
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⇒ “2.7 Renewing valve stem seals with cylinder head installed”, p by
co Vo
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page 112
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⇒ “2.8 Renewing valve stem seals with cylinder head removed”,
page 116
⇒ “2.9 Valves”, page 119
2.1 Assembly overview - valve gear

Sharan 2011 ➤
1 - Valve
❑ Do not rework; only
grinding-in is permissi‐
ble
❑ Mark installation posi‐
tion for re-installation.
❑ Checking ⇒ page 120
❑ Valve dimensions
⇒ page 119
❑ Checking valve guides
⇒ page 119
2 - Cylinder head
3 - Valve stem seal
❑ Renewing with cylinder
head installed
⇒ page 112 .
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head removed lkswage es n
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⇒ page 116 . byV ua
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4 - Valve springs auth or
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5 - Valve spring plate
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6 - Valve cotters
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7 - Cap
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❑ Renew
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❑ Removing: With retain‐
spec
ing frame installed,
es, in part or in w
pierce one side of cap
t to the co
with an awl and pry out.
❑ Installing: Drive in with‐
out sealant using an ap‐ rrectness of i
propriate thrust piece.
l purpos
❑ Drive in depth 1 to 2 mm
8 - Oil seal
nform
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9 - Exhaust camshaft
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❑ Measuring axial clearance ⇒ page 108 .

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❑ Measuring radial clearance ⇒ page 109

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10 - Bolt
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❑ Specified torque and tightening sequence ⇒ page 100 cop Vo
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11 - Ladder frame
AG.
❑ With integrated camshaft bearings.

12 - Inlet camshaft
❑ Measuring axial clearance ⇒ page 108 .
❑ Measuring radial clearance ⇒ page 109
13 - Roller rocker fingers
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.
2. Valve gear 99
Sharan 2011 ➤
14 - Retaining clip
❑ For hydraulic compensation element.
15 - Hydraulic compensation element
❑ Mark installation position for re-installation.
❑ Lubricate contact surfaces before installing.
Retaining frame - specified torques and installation sequence

• The retaining frame must make
contact with the cylinder head over
the entire contact surface.
2) -1 … 24- 10 Nm
AG. Volkswagen AG d
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es, in part or in w
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Cop py
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by lksw
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Prote AG.

Sharan 2011 ➤
2.2 Removing and installing camshafts

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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♦ Diesel injection pump locking pin - 3359-

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♦ Puller - T10052-
h re
hole
spec
♦ Camshaft fitting tool - T40094-

es, in part or in w
t to the co
♦ Camshaft clamping tool - T40095-

♦ Camshaft fitting tool - T40096-
rrectness of i
l purpos
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Cop py
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2. Valve gear
olkswagen AG
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Sharan 2011 ➤ olks
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d engine (2.0 l, EA189 Gen II) - Edition
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♦ Torque wrench - V.A.G
ss
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♦ Torque wrench - V.A.G 1332/-
nform
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Cop py
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Prote AG.
♦ Silicone adhesive sealant - D 176501 A1-
2.2.1 Removing
– Take toothed belt off camshaft and high-pressure pump
⇒ page 77 .
– Remove securing bolts for camshaft toothed belt pulley -1-.
– Detach camshaft pulley from hub.

Sharan 2011 ➤
– Counterhold hub with counterhold - T10051- and loosen se‐

curing bolt -1- of hub.
– Loosen hub securing bolt about 2 turns.
– Fit puller - T10052- and align it with holes in hub.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
When doing this, hold puller with 30 mm spanner.swagen AG. Volkswagen AG does
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– Remove hub from taper of camshaft.orise nte
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– Remove vacuum pump ⇒ page s95sa . c
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nl
pt
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– Remove securing bolts of retaining frame in sequence
itte
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-24 … 1-.
erm
ab
ility
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– Remove retaining frame.
wit
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– Carefully take out camshafts.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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2.2.2 Installing Cop py
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Note
AG.
Seal parting surface between retaining frame and cylinder head

using silicone adhesive sealant - D 176 501 A1- .
2. Valve gear 103

Sharan 2011 ➤
Caution
The camshafts may be installed only with the camshaft fitting

tool - T40094- as described below. The axial bearings in the
retaining frame will otherwise be damaged beyond repair and
the cylinder head will have to be renewed.
– Remove sealant residues on cylinder head and retaining

frame, e.g. using a plastic rotary brush.
Caution
Make sure that no sealant residue gets into the cylinder head
or the bearings.
– Clean sealing surfaces; they must be free of oil and grease.

– Lubricate running surfaces of camshafts.
If not already done, set up camshaft fitting tool - T40094- as fol‐
lows:
– Remove supports -T40094/3-, -T40094/4- and -T40094/5-
from base plate. Threaded connection is accessible from be‐
low. agen
AG. Volkswagen AG d
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Note tho
tee
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ss
If the supports of the camshaft fitting tool - T40094- are not
ce
e
nl
marked at present, mark the removed supports, e.g. with number pt

du
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stamps, so they can be fitted in the original positions later. y li

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– Install supports -T40094/9- and -T40094/10- instead at vacant

t to the co
outer places.
– Place support -T40094/2- at position labelled “A” and support
-T40094/1- at position labelled “F”.
rrectness of i
– First position inlet camshaft as illustrated. Ensure that inden‐

l purpos
tation -arrow- for cylinder head bolt faces »outwards«.

nf
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Set 0.50 mm feeler gauge in place and push support

-T40094/8- into groove on inlet camshaft.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Now set exhaust camshaft in place and lock by inserting
-cover T40094/11- into groove -arrow-.
t to the co
– Fit clamping tool - T40096/1- onto exhaust camshaft gears.
rrectne
Caution
ss
Ensure that the clamping jaw marked with an arrow is seated
o
cial p
f
on the wider gear.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
– Tighten clamping tool - T40096/1- using knurled thumb wheel

p
cum
r
fo
so that faces of gear teeth are in alignment. If necessary, use
en
ng
t.
yi
13 mm open-end spanner.
Co
Cop py
t. rig
gh
– Slide exhaust camshaft towards inlet camshaft until gear teeth
ht
pyri by
Vo
o
engage. by c lksw
cted agen
Prote AG.
– Fit retaining frame onto camshafts.
• All camshaft bearings must be seated on the camshafts.
– Set clamping tool - T40095- in place as illustrated in order to

hold camshafts in position in retaining frame.
– Remove cover - T40094/11- .
– Pull support - T40094/8- out of inlet camshaft groove.
2. Valve gear 105

Sharan 2011 ➤
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

2 mm).
– Apply beads of sealant (approx. 2…3 mm wide) -arrows- onto
clean sealing surfaces of cylinder head as illustrated.
Caution
Risk of soiling camshaft bearings due to surplus sealant and

risk of sealing oil supply bores.
♦ Do not apply sealant beads thicker than specified.
♦ In area of oil supply bores -arrow- for retaining frame,
make sure that these are not sealed due to surplus seal‐ AG. Volkswagen AG d
agen
ant. Volksw
oes
not
by gu
ara
ed nte
oris eo
th
au ra
c
Sealant bead for retaining frame ss
ce
e
nl
pt
du
– Take camshafts out of camshaft fitting tool - T40095- together
an
itte
y li
with retaining frame and clamping tool - T40094- .
erm
ab
ility
ot p
– Carefully position camshafts and retaining frame in cylinder
wit
, is n
head.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– First tighten securing bolts of retaining frame hand-tight in se‐

quence -1 … 24-.
• The retaining frame should make contact with the cylinder
head over the complete surface.
– Tighten retaining frame bolts to final torque in the sequence
-1 … 24-. Specified torque: 10 Nm
– Remove clamping tool - T40095- and camshaft fitting tool -
T40096/1- .
– Renew camshaft oil seal ⇒ page 109 .
– Using a suitable drift, knock new sealing cap (core plug)
⇒ Item 7 (page 99) in cylinder head until flush.
Perform further installation in reverse order, paying attention to
the following:
Caution
Avoid damage to valves and piston crowns after working on

valve gear.
♦ Because hydraulic compensation elements have to settle,
engine must not be started for approx. 30 minutes after
installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
– Fit hub onto camshaft.
– Tighten hub securing bolt -1- to 100 Nm. To do this, use coun‐
terhold - T10051- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Valve gear 107

Sharan 2011 ➤
– Push camshaft toothed belt pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
– Hand tighten securing bolts -1- to camshaft toothed belt pulley

so that there is no play.
– Lock hub using locking pin - 3359- .
– Install toothed belt and adjust valve timing ⇒ page 77 .
– Install vacuum pump ⇒ page 95 .
– Install fuel filter.
2.3 Measuring axial clearance of camshaft

♦ Universal dial gauge holder - VW 387-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
Procedure
te
sd
iva
o
r
– Remove retaining frame ⇒ page 101 .

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Fasten dial gauge - VAS 6079- to cylinder head with universal

dial gauge bracket - VW 387- as shown in the illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048 to 0.118 mm.
• Wear limit: 0.17 mm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
2.4 Measuring radial clearance of cam‐ aut
hor eo
ra
shafts ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Plastigage
ility
ot p
wit
Procedure
, is n
h re
hole
– Remove roller rocker finger.
spec
es, in part or in w
– Remove bearing cap and clean crankshaft journal.
t to the co
– Place a length of Plastigage corresponding to the width of the
bearing on the journal to be measured or into the bearings.
rrectness of i
• The Plastigage must lie in the middle of the bearing.
l purpos
– Fit retaining frame and tighten to 10 Nm ⇒ page 100 without

twisting crankshafts.
nform
ercia
– Remove retaining frame.

m
at
om
io
– Compare width of Plastigage with the measurement scale.
n
c
in t
or
his
e
• Radial clearance: 0.035 to 0.085 mm.

at
do
priv
2.5 Removing and installing camshaft oil seal

um
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Valve gear 109

Sharan 2011 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
♦ Fitting tool - V.A.G 10-203- at

om
ion
c
in t
♦ Seal puller - 3240-

or
his
ate

do
priv
cum
for

en
ng
t.
yi Co
op
♦ Bolt M12 x 1.5 x 75
C py
ht. rig
rig ht
py by
Removing co Vo
by lksw
cted agen
Prote AG.
– Take toothed belt off camshaft and high-pressure pump
⇒ page 77 .
– Remove camshaft pulley and hub ⇒ page 101 .

AG. Volkswagen AG d
ksw
agen oes
not
Sharan 2011 ➤
ol
4-cylinder common byV rail engine (2.0 l, EA189 Gen guII) - Edition 10.2018
a
ed ran
ris tee
ho
– Insert thrust piece -3240/1- into camshaft.
aut or
ac
ss
– Unscrew inner part of oil seal extractor -3240- 2 turns (approx.
ce
le
un
pt
3 mm) from outer part, and lock it in place using knurled screw.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
nform
ercia
– Loosen knurled screw and turn inner part against camshaft

m
a
com
ti
until oil seal is pulled out.
on in
r
te o
thi
Installing
s
iva
do
r
rp
cum
fo
en
g
Note
n
t.
yi Co
Cop py
ht. rig
Do not be additionally oil or grease the oil seal sealing lip. rig ht
py by
co Vo
by lksw
cted agen
Prote
– Remove oil residue from camshaft journal using a clean cloth.
AG.
– Fit guide sleeve of fitting tool - 10 - 203- onto camshaft as

shown in illustration.
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
– Press seal in to stop using thrust piece from fitting tool 10-203
and bolt M12×1.5x75.
– Install camshaft pulley and hub ⇒ page 101 .
– Install toothed belt and adjust valve timing ⇒ page 77 .
2. Valve gear 111

Sharan 2011 ➤
2.6 Checking hydraulic compensation ele‐

ments
Note
♦ The hydraulic compensation elements cannot be repaired.

♦ Irregular valve noise during starting is normal. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
Special tools and workshop equipment required ir se
d b ua
ran
o tee
h
♦ Feeler gauge aut or
ac
ss
Procedure
ce
e
nl
pt
du
an
itte
– Start engine and run until the radiator fan has switched on
y li
erm
ab
once.
ility
ot p
– Increase engine speed to about 2500 rpm for 2 minutes; per‐
wit
, is n
h re
form road test if necessary.
hole
spec
es, in part or in w
t to the co
Note
If the irregular valve noises stop but recur repeatedly during short
rrectness of i
journeys, the oil retention valve must be renewed. The oil reten‐
tion valve is located in the oil filter bracket ⇒ page 137 .
l purpos
– If the hydraulic compensation elements are still noisy, find out
nf
ercia
which is the defective compensation element as follows:
orm
m
atio
m

o
n in
or c
– Turn crankshaft by the bolt for the toothed belt wheel until cam
thi
te
sd
of supporting element to be tested is facing upwards.
iva
o
r
rp
cu
o
– Press roller rocker finger downwards -arrow- to check clear‐
m
f
en
ng
t.
ance between cam and roller rocker finger. Cop
yi Co
py
t. rig
– If a 0.20 mm feeler gauge can be inserted between cam and gh ht
yri by
roller rocker finger, renew hydraulic compensation element. cop Vo
by lksw
cted agen
Prote AG.
Concluding measures
2.7 Renewing valve stem seals with cylinder

head installed

Sharan 2011 ➤
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
♦ Removal and installations device for valve cotters - VAS 5161-
s c
ce
le
with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1-

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
♦ Bolt M6×30 (qty. 2)

o
cial p
f inform
Procedure
mer
atio
m
– Remove all glow plugs ⇒ page 318 .

o
n
c
i
or
– Remove camshafts ⇒ page 101 .

thi
te
sd
iva
– Mark allocation of roller rocker fingers and hydraulic compen‐

o
pr
cum
r
fo
sation elements for reinstallation.

en
ng
t.
yi Co
– Remove roller rocker fingers together with hydraulic compen‐ Cop py
ht. rig
sation elements and place down on a clean surface. rig ht
py by
co Vo
by lksw
– Set piston of respective cylinder to “bottom dead centre”. Prote
cted AG.
agen
2. Valve gear 113

Sharan 2011 ➤
– Place guide plate -VAS 5161/23- onto cylinder head.

– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
– Screw sealing pins -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into relevant glow
plug thread.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
– Insert drift -VAS 5161/3- into guide
aut
h plate and use a plastic eo
ra
hammer to knock loose the firmly
ss seated valve cotters. c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Screw toothed piece -VAS 5161/6- with hooking fork -

s
VAS 5161/5- into guide plate.

s o
cial p
f in
– Push sleeve -VAS 5161/23-1- onto assembly cartridge -

form
mer
VAS 5161/8- .
atio
m
– Connect adapter to compressed air supply using a commer‐

o
n
c
i
or
cially available union and apply pressure continuously.

thi
te
sd
va
• Minimum pressure: 6 bar.

i
o
pr
cum
r
fo
– Attach pressure fork -VAS 5161/2- to toothed piece and press

en
ng
t.
yi Co
assembly cartridge down. t. Cop py
rig
gh ht
– At the same time, turn knurled screw of assembly cartridge yri
p by
o Vo
by c
clockwise until tips engage in valve cotters.
lksw
cted agen
Prote AG.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge with knurled spacer ring.
– Remove valve spring and valve spring plate.

Sharan 2011 ➤
– Pull off valve stem seal using valve stem seal puller - 3364- .
Caution
Risk of damage when installing valve stem seals.

♦ Place plastic sleeve -A-, enclosed with new valve stem
seals -B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.

– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If the valve cotters have been removed from the assembly agen
AG. Vcar‐
olkswagen AG
does
tridge, they must first be inserted into the valveVoinsertion
lksw device - not
gu
VAS 5161/18- . sed by ara
n i tee
or
• Larger diameter of valve cotters faces
au
th upwards. or
ac
ss
– Insert valve spring and valve spring plate.
ce
e
nl
pt
du
an
– Press assembly cartridge onto valve cotter insertion device

itte
y li
erm
from above and pick up valve cotters.

ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Insert assembly cartridge into guide plate -VAS 5161/23-

again.
rrectness of i
– Press pressure fork downwards and pull knurled screw up‐

l purpos
wards, turning it clockwise and anticlockwise. This inserts the

valve cotters.
nf
ercia
– Reduce pressure on pressure fork whilst pulling on knurled

or
screw.
m
m
atio
m
– Repeat procedure on each valve.

o
n in
or c
thi
e
Installing
t
sd
iva
o
r
rp
cu
Installation is carried out in the reverse order; note the following:

o
m
f
en
ng
t.
yi
– Ensure that all roller rocker fingers contact valve stem ends
Co
op py
correctly and are clipped into relevant hydraulic compensation
. C rig
ht ht
rig
elements. py by
co Vo
by lksw
cted agen
– Install camshafts ⇒ page 101 . Prote AG.
– Install glow plugs ⇒ page 318 .
2. Valve gear 115

Sharan 2011 ➤
AG. Volkswagen G d
ksw
agen (2.0 l, EA189AGen oeII)
s n - Edition 10.2018 ol ot g
yV ua
db ran
2.8 Renewing valve stem seals with cylinder head removed
e
ris tee
tho or
au ac
ss
ce
e
Special tools and workshop nl
pt
du
an
equipment required
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Valve stem seal puller - 3364-

♦ Valve stem seal fitting tool - 3365-
♦ Removal and installation device for valve cotters - VAS 5161-
with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Bolt M6×30 (qty. 2)
Procedure
– Remove camshafts ⇒ page 101 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .

Sharan 2011 ➤
ks on cylinder head tensioning wage es
– Tension cylinderyheadVol
not device as
gu
shown in illustration.
ris
ed b ara
nt ee
tho o
– Connects acylinder
u head tensioning device to compressed air.
ra
c s
ce
e
– Use lever -arrow- to slide air cushion under combustion cham‐

nl
pt
du
ber from which valve stem seal is to be removed.
an
itte
y li
erm
ab
– Allow compressed air to flow into air cushion until it lies against
ility
ot p
valve disc.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Place guide plate -VAS 5161/23- onto cylinder head.
rrectness of i
– Tighten guide plate on intake manifold side by hand using
l purpos
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until

it makes contact.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Insert drift -VAS 5161/3- into guide plate and use a plastic cop Vo
by lksw
hammer to knock loose the firmly seated valve cotters. cted agen
Prote AG.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge with knurled spacer ring.
– Remove valve spring and valve spring plate.
2. Valve gear 117

Sharan 2011 ➤
– Pull off valve stem seal using valve stem seal puller - 3364- .
Caution
Risk of damage when installing valve stem seals.

♦ Place plastic sleeve -A-, enclosed with new valve stem
seals -B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.

– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device -
VAS 5161/18- .
. Volkswagen AG
• Larger diameter of valve cotters faces upwards.
ksw
agen
AG does
not
Vol gu
– Insert valve spring and valve spring plate. by ara
ed nte
oris eo
th
– Press assembly cartridge onto valve au cotter insertion device ra
c
ss
from above and pick up valve cotters.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Insert assembly cartridge into guide plate -VAS 5161/23-

spec
again.
es, in part or in w
t to the co
– Press pressure fork downwards and pull knurled screw up‐

wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
rrectness of i
– Reduce pressure on pressure fork whilst pulling on knurled

l purpos
screw.
– Repeat procedure on each valve.
nf
ercia
or
Installing
m
m
atio
om

n in
or c
thi
e
– Ensure that all roller rocker fingers contact valve stem ends
t
sd
iva
correctly and are clipped into relevant hydraulic compensation

o
r
rp
cu
elements.
o
m
f
en
ng
t.
yi Co
– Install camshafts ⇒ page 101 . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
2.9 Valves
⇒ “2.9.1 Valve dimensions”, page 119
⇒ “2.9.2 Reworking valve seats”, page 119
⇒ “2.9.3 Checking valve guides”, page 119
⇒ “2.9.4 Checking valves”, page 120
2.9.1 Valve dimensions

AG. Volkswagen AG d
agen oes
olksw not
V gu
by
Note ised ara
nte
or eo
h
ut ra
Never rework the inlet and exhaust valves. Only lapping-in is per‐
s a c
s
mitted.
ce
e
nl
pt
du
an
itte
y li
erm
Dimension Inlet valve Outlet valve
ab
ility
ot p
∅a mm 28.10 26.00
wit
, is n
h re
∅b mm 5.975 5.965
hole
spec
c mm 99.30 99.10
es, in part or in w
t to the co
α ∠° 45 45
rrectness of i
2.9.2 Reworking valve seats
l purpos
Note
nform
ercia
Valve seats must not be reworked due to the very narrow toler‐
m
at
om
i
ances.
on
c
in t
or
his
ate
2.9.3 Checking valve guides do

priv
cum
for
en

ng
t.
yi Co
op py
♦ Universal dial gauge holder - VW 387- t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Valve gear 119

Sharan 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
Procedure
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
♦ If the valve is renewed as part of a repair, use a new valve for
t to the co
the measurement.
♦ Due to differing stem diameters, only use intake valve in intake
rrectne
guide and exhaust valve in exhaust guide.
s
– Attach dial gauge - VAS 6079- with universal dial gauge holder
s o
- VW 387- to cylinder head.
cial p
– Insert valve into valve guide. f inform

mer
atio
m
• The end of the valve stem must be flush with the guide.
o
n
c
i
or
n thi
– Determine rock.
te
sd
iva
o
r
• Wear limit: 1.0 mm.

p
cum
r
fo
en
ng
– If the wear limit is exceeded, repeat the measurement with

t.
yi Co
op
new valves.
C py
t. rig
gh ht
yri by
– Renew cylinder head if wear limit is still exceeded.
op Vo
by c lksw
cted agen
Prote AG.
Note
Valve guides cannot be exchanged.
2.9.4 Checking valves

– Check for scoring on valve stems and valve seat surfaces.
– Exchange valve if significant scoring can be seen.

Sharan 2011 ➤
17 – Lubrication
1 Engine oil:
Note
The oil level must remain below the max. mark - danger of dam‐
age to catalytic converter! Markings ⇒ page 121 .
Drain engine oil ⇒ Maintenance ; Booklet ; Engine oil: Drain or

extract; renew oil filter and replenish engine oil .
Engine oil specifications ⇒ Maintenance ; Booklet ; Service ta‐
bles . n AG. Volkswagen A ge G do
swa es n
⇒ “1.1 Oil capacities”, page
by
Vol 121
k ot g
ua
d ran
ise
⇒ “1.2 Checking tengine
ho
r oil level”, page 121 tee
or
au ac
ss
1.1 Oil capacities
ce
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pt
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d
With oil filter change: 4.3 l

itte
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rm
ab
Without oil filter change: 4.0 l
pe
ility
ot
wit
, is n
1.2 Checking engine oil level

h re
hole
spec
es, in part or in w
Note t to the co
The oil level may be in area -d- due to the infiltration of fuel in the
rrectness of i
engine oil as a result of unfavourable driving conditions after fill‐

ing. This is a perfectly normal and self-regulating characteristic.
l purpos
It is not necessary to adjust the engine oil level.

nform
ercia
1 - Min. mark
m
a
com
2 - Max. mark
tion in
r
te o
a - Oil level in min. mark area: replenish engine oil!

thi
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iva
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b - Oil level in middle range: can be topped-up with engine oil.

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rp
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c - Oil level in max. mark area: do not replenish engine oil.

n
t.
yi Co
Cop py
d - The oil level may be in this area as a result of particular driving
t. rig
gh ht
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conditions. p by
co Vo
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cted agen
Prote AG.
1. Engine oil: 121

Sharan 2011 ➤
2 Parts of lubrication system
Note
♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To avoid any sub‐
sequent damage, the following work must be carried out fol‐
lowing the repair: carefully clean oil channels and renew oil
spray jets, engine oil cooler and oil filter.
♦ Oil capacities, oil specifications, viscosity grades ⇒ Mainte‐
nance tables .
⇒ “2.1 Assembly overview - oil pump, sump, balance shaft mod‐

ule”, page 122
⇒ “2.2 Removing and installing oil level and oil temperature send‐
er G266 ”, page 126
⇒ “2.3 Removing and installing oil sump”, page 126
wage es n
⇒ “2.4 Removing and installing oil pump”, page
yV
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ua
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e
⇒ “2.5 Removing balancer shaft module”,horis page 131 tee
aut or
ac
⇒ “2.6 Installing a new balancer shaft
ss module”, page 133
ce
le
un
pt
⇒ “2.7 Installing a previously used balancer shaft module again”,
an
d
itte
page 135
y li
rm
ab
pe
ility
2.1 Assembly overview - oil pump, sump, balance shaft module
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
122 Rep. gr.17 - Lubrication

Sharan 2011 ➤
1 - Seal
❑ Permanently attached
to drain plug
2 - Oil drain plug, 30 Nm
3 - Sump
⇒ page 126
4 - 9 Nm
5 - Suction line
❑ Clean strainer if soiled
6 - O-ring
❑ Renew
7 - Oil pump
⇒ page 130
❑ Before installing, check
that the two dowel
sleeves for centring oil
pump on balancer shaft
module are fitted.
8 - Input shaft
❑ For oil pump.
9 - Retaining ring
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
10 - Spur gear AG. Volkswagen AG d
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❑ For balancer
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11 - 20 hNmris + turn 90° further nte
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❑ss a Renew ac
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12 - Thrust washer
pt
du
an
itte
❑ For intermediate gear wheel.

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ab
❑ Renew
ility
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❑ Fitting position ⇒ page 125

, is n
h re
hole
❑ To install intermediate gear wheel, secure to balancer shaft module with grease.
spec
es, in part or in w
13 - Intermediate gear
t to the co
❑ Renew
❑ A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through
rrectness of i
wear.
l purpos
❑ Installation position: Part number must be visible.

❑ Make sure thrust washer is seated correctly ⇒ page 125 .
nform
ercia
14 - 90 Nm + 90°
m
❑ With washer
at
om
ion
❑ Renew
c
in t
or
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te
15 - Hub
a
do
priv
❑ For intermediate gear wheel.

um
for
en
ng
t.
❑ Renew
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Parts of lubrication system 123

Sharan 2011 ➤
16 - Crankshaft sprocket
17 - Balancer shaft module
❑ Removing ⇒ page 131
❑ Reinstalling previously run balancer shaft module ⇒ page 135 .
❑ Installing new balancer shaft module ⇒ page 133 .
❑ Before installing, check that the two dowel sleeves
wage
n AG. Volkfor centring
swagen AG
doebalancer
s no
shaft module on cylinder block
s
are fitted. yV
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18 - Bolt tho
ris e or
u
❑ Renew ss
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ce
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un
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19 - Dowel sleeves
erm
ab
ility
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20 - 9 Nm
wit
is n
h re
21 - Oil extraction pipe
ole,
spec
22 - 9 Nm
t to the co
23 - Seal
❑ Renew
rrectne
24 - Oil level and oil temperature sender - G266-
ss o
cial p
25 - 9 Nm
f inform
❑ Self-locking
mer
atio
❑ Renew
om
n
c
i
or
n
26 - Bolt
thi
te
sd
a
❑ Renew
iv
o
pr
cum
r

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ng
t.
yi Co
Cop py
t. rig
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Sump - specified torque and tightening sequence cop Vo
by lksw
cted agen
Prote AG.
Note
Renew oil sump bolts.
– Tighten bolts in 3 stages:

1) -1 … 20- In diagonal sequence to 5 Nm
2) -Arrows- 40 Nm
15 Nm

Sharan 2011 ➤
Thrust washer installation position
Caution
Risk of thrust washer slipping behind intermediate gear wheel.

♦ When installing intermediate agen
AG. gear
Volkswwheel,
agen AGmake sure that
does
thrust washer -A- yV
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lksw not slip out of balancer nshaft
ot g mod‐
ule indentations ed -arrows- and subsequently become
b ua
ranjam‐
ris
med. If necessary,
tho fix in place with grease on balancer tee
or
shaft module.
ss
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nl
pt
du
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itte
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ab
Tightening sequence - balancer shaft module with 8 bolted con‐
ility
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nection points
wit
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h re
– Tighten bolts of balancer shaft module as follows:
hole
spec
es, in part or in w
t to the co
1) -1 … 8- Hand-tighten in sequence
2) -1 … 8- Initially tighten in sequence to 6 Nm
rrectness of i
3) -1 … 4- Tighten to 20 Nm
l purpos
4) -5- Tighten to 13 Nm
nform
ercia
m
at
om
7) -8- Tighten to 20 Nm ion

c
in t
r
8) -1 … 8- Turn bolts 90° further in sequence us‐

o
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te
ing a fixed wrench

a
do
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cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
Tightening sequence - balancer shaft module with 6 bolted con‐ py by
co Vo
nection points
by lksw
cted agen
Prote AG.
– Tighten bolts of balancer shaft module as follows:
1) -1 … 6- Hand-tighten in sequence
2) -1 … 6- Initially tighten bolts in sequence to
6 Nm
3) -1 … 4- Tighten to 20 Nm.
4) -5 and 6- Tighten to 13 Nm
5) -1 … 6- Turn bolts 90° further in sequence us‐
ing a fixed wrench

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byV ua
d ran
Sharan 2011 ➤ ho
ir se tee
t or
4-cylinder common rail engine (2.0 l, EA189 Gen sII)
au - Edition 10.2018 ac
s
ce
le
un
pt
2.2 Removing and installing oil level and oil
an
d
itte
y li
temperature sender - G266-
rm
ab
pe
ility
ot
Removing
wit
, is n
h re
hole
– Drain engine oil ⇒ Maintenance ; Booklet .
spec
es, in part or in w
– Disconnect electrical connector -3-.
t to the co
– Unscrew bolts -1- and remove oil level and oil temperature
sender - G266- -item 4-.
rrectness of i
Installing
l purpos
⇒ “2.1 Assembly overview - oil pump, sump, balance shaft
nform
ercia
module”, page 122 .
m
a
com
tion in
r
te o
thi
s
iva
Note
do
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rp
cum
fo
en
g
Renew seal -2- and self-locking bolts -1-.

n
t.
yi Co
Cop py
t. rig
gh
– Replenish engine oil, and check oil level ⇒ Maintenance ;
ht
pyri by
Vo
o
Booklet .
c by lksw
cted agen
Prote AG.
2.3 Removing and installing oil sump

♦ T-bar and socket, 10 mm - 3185-
♦ Torx bit - T10058-
♦ Hand drill with plastic brush

♦ Sealant ⇒ Electronic Parts Catalogue
♦ Safety glasses

Sharan 2011 ➤
Removing
– Drain engine oil ⇒ Maintenance ; Booklet .
– Remove air hose; loosen hose clip -2- and raise retaining clip
-1- for this.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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ss c
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e
nl
pt
du
an
itte
y li
erm
ab
– Unscrew bolts -arrows-.
ility
ot p
wit
, is n
– Free coolant hose -3-.
h re
hole
spec
– Release hose clip -2-.
es, in part or in w
t to the co
– Disconnect electrical connector -1- on charge pressure sender
- G31- and remove right air pipe.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Unscrew bolt -arrow- and push coolant circulation pump 2 -
op Vo
by c lksw
V178- to the side. cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
Sharan 2011 ut
h ➤
o eo
ra
a
4-cylinder
s common rail engine (2.0 l, EA189 Gen II) - Edition
s c 10.2018
ce
le
un
pt
– Unscrew bolt -arrow- on left air pipe.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Disconnect electrical connector -arrow- on oil level and oil
mer
temperature sender - G266- .
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Open fasteners -arrows- and remove noise insulation -1- for

sump.
– Unscrew bolts -arrows- of sump to gearbox connection.

– Slacken bolts -1 … 20- in diagonal sequence and remove.
– Release sump carefully from adhesive.
Installing
Caution
Danger of soiling lubrication system and bearings.

♦ Cover open parts of engine.
WARNING
Risk of eye injury.

♦ Wear safety goggles.

Sharan 2011 ➤
– Remove sealant residues from sump and cylinder block using

rotating plastic brush or similar.
– Clean sealing surfaces; they mustenbe
AGoil
. Voand
lkswagrease
gen AG free.
wag does
olks not
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ara
ed nte
ris
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ss
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co
Check the expiry date of the sealant.
rrectness of i
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
l purpos
2 mm).
nf
ercia
o
Caution
rm
m
atio
m
Danger of blocking lubrication system with excess sealant.

o
n in
or c
thi
e
♦ Do not apply sealant bead thicker than specified.

t
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
– Apply bead of sealant onto clean sealing surface of sump as
yi Co
op py
illustrated.
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ht ht
rig by
copy Vo
by lksw
• Thickness of sealant bead: 2…3 mm. cted agen
Prote AG.
Note
♦ Take particular care when applying sealant bead in area of

rear sealing flange -arrows-.
♦ Oil sump must be installed within 5 minutes after applying
sealant.
– Mount oil sump.

• The sump must be flush with the gearbox flange at the inter‐
mediate plate.

lkswage es n
o ot g
byV ua
d ran
ir se
Sharan 2011 ➤ tho tee
or
u
ss
a
(2.0 l, EA189 Gen II) - Edition 10.2018 ac
ce
le
un
pt
Sump - specified torque and tightening sequence
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
1) -1 … 20- In diagonal sequence to 5 Nm
spec
es, in part or in w
2) -Arrows- 40 Nm
t to the co
15 Nm
rrectness of i
l purpos
Note
nform
ercia
♦ When installing sump with engine removed, ensure that sump

is flush with cylinder block at flywheel end.
m
a
com
tio
♦ Allow sealant to dry for approx. 30 minutes after installing
n in
r
te o
sump. Only then fill with engine oil.
thi
s
iva
do
r
rp
cum
– Install coolant circulation pump 2 - V178- .
fo
en
ng
t.
yi
– Install air pipes ⇒ page 218 .
Co
Cop py
t. rig
gh ht
– Installing intake hoses with screw-type clips ⇒ page 218 . yri
p by
co Vo
by lksw
cted
– Fit noise insulation ⇒ Rep. gr. 50 .
agen
Prote AG.
– Replenish engine oil, and check oil level ⇒ Maintenance ;

Booklet .
2.4 Removing and installing oil pump

♦ Circlip pliers (commercially available)
♦ M3 bolt
Removing
– Unscrew bolts -arrows- and pull suction line off oil pump.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
e d b Sharan
ara 2011 ➤
nt
ris
4-cylinder commonut
ho rail engine (2.0 l, EA189 Gen II) - Editione10.2018eo
ra
s a c
s
– Remove circlip -1- with circlip pliers.
ce
le
un
pt
an
d
itte
– Pull drive shaft -2- out of oil pump using a magnet -arrow-.
y li
rm
ab
pe
– Unscrew bolts -3, 4, 5- and remove oil pump.
ility
ot
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
Bolt on intermediate gear wheel must not be loosened.
rrectness of i
Installing
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
♦ Renew O-ring.
en
ng
t.
yi Co
♦ Renew damaged or overstretched circlip. Cop py
ht. rig
rig ht
♦ The retaining ring must seat in the base of the groove.
py by
co Vo
by lksw
cted agen
Prote AG.
– Insert dowel sleeves if oil pump has no dowel sleeves

-arrows-.
– Insert dowel sleeves if balancer shaft module has no dowel
sleeves for centring oil pump.
2.5 Removing balancer shaft module

Procedure
– Pull out oil dipstick.
– Remove vibration damper ⇒ page 30 .

Sharan 2011 ➤
lkswage es n
Caution d byV
o ot g
ua
ran
ir se tee
ho
Risk of destruction due to toothedau belt jumping.
t or
ac
ss
♦ Only turn crankshaft in engine direction of rotation.
ce
le
un
pt
an
d
itte
y li
erm
ab
– Turn crankshaft at bolt for toothed belt pulley until crankshaft
ility
ot p
is at “TDC”.
wit
is n
h re
ole,
– Lock crankshaft in position with crankshaft stop - T10050- .
spec
• The markings on the toothed belt pulley -2- and the crankshaft
t to the co
stop -1- must align -arrow-. When doing this, the pin of the
crankshaft stop must engage in the drilling of sealing flange.
rrectne
Note
ss o
cial p
f
The crankshaft stop can be pushed onto the toothed belt sprocket
in
only from the face side.
form
mer
atio
m

o
n
c
i
or
n thi
e
– Unscrew bolts in sequence -8 … 1- respectively -6 … 1-, and

t
sd
va
remove balancer shaft module with oil pump.

i
o
pr
cum
r
fo
en
ng
t.
yi
Balancer shaft module with 8 threaded connection points
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
Note
♦ Installing a new balancer shaft module ⇒ page 133 .

♦ Installing a previously used balance shaft module
⇒ page 135 .
2.6 Installing a new balancer shaft module

♦ Locking device - T10255-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
Procedure
pe
ility
ot
wit
• Specified torques
, is n
h re

hole
spec

es, in part or in w
t to the co
• Crankshaft locked in position with crankshaft stop - T10050- .

rrectness of i
Note
l purpos
♦ The spur gear drive of the balance shaft module must be in‐
stalled with a backlash of 0.038 … 0.072 mm.
nform
ercia
♦ A coating of correct thickness is applied to the new intermedi‐

m
ate gear wheel to set the correct backlash. The coating is

a
com
tio
applied in part around the teeth.

n in
r
te o
thi
♦ The coating is quickly worn away, which sets the correct back‐
s
iva
do
lash.
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rp
cum
fo
en
♦ A new balance shaft module must always be installed with a

ng
t.
yi Co
new intermediate gear wheel with coating. t. Cop py
rig
gh ht
♦ If a further tightening angle is specified for certain bolts, these pyri by
Vo
o
by c
must be renewed.
lksw
cted agen
Prote AG.

Sharan 2011 ➤
Caution
AG. Volkswagen AG d
agen oes
lksw not
Risk of thrust washer slippingd by behind intermediate gear wheel.
Vo gu
ara
ise nte
r
♦ To fit balance shaftut
ho module, do not loosen intermediate eo
ra
gear wheel bolt
ss a more than specified. Thrust washer in‐ c
stallation position ⇒ page 125
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Loosen bolt -1- for intermediate gear wheel approx. 45°.
ility
ot p
wit
, is n
– Insert dowel sleeves if no dowel sleeves for centring balance
h re
shaft module are fitted on cylinder block.
hole
spec
– Place balancer shaft module on cylinder block.
es, in part or in w
t to the co
• Coating on intermediate gear wheel must not be damaged.
– Tighten bolts for balance shaft module:
rrectness of i
l purpos
⇒ page 125
nform
ercia
⇒ page 125
m
at
om
io
– Lock balance shaft with locking tool - T10255- ; if necessary,
n
c
in t
or
turn balance shaft.
his
ate
do
riv
• Locking tool pin must engage in groove in balancer shaft when

p
cum
or
doing this.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Carefully fit balance shaft gear wheel onto balance shaft; push
intermediate gear wheel slightly to side for this.
• Coating on intermediate gear wheel must not be damaged.
• If possible, threaded holes of balance shaft should be located
centrally in elongated holes of balance shaft gear wheel.
Note
If elongated holes in balance shaft gear wheel cannot be aligned

to threaded holes, balance shaft gear wheel must be turned by
respective number of teeth and fitted again.
– Tighten bolts -arrows- for balance shaft gear wheel.

– Remove locking tool - T10255- .

Sharan 2011 ➤
Note
The following 3 procedures must be performed simultaneously

(2nd mechanic required).
– Press intermediate gear wheel -3- forcefully (with assistance

of a wooden rod if necessary) in -direction of arrow- into spur
gear teeth -2- and balance shaft gear wheel -1-.
– Turn balance shaft gear wheel slightly anticlockwise whilst do‐
ing this.
– Tighten bolt for intermediate gear wheel.
– Remove crankshaft stop - T10050- .
Note
No backlash may be perceptible after installing intermediate gear

wheel. This can be checked by hand using light force.
Now continue installing in reverse order of removal, observing the

following:
– Install vibration damper ⇒ page 30 .
2.7 Installing a previously used balancer

shaft
swa
gmodule
en AG. V
olksagain
wagen AG
does
k not
Vol g
Special tools
se
d b and workshop equipment required
y ua
ran
i tee
or
♦ Locking
au
th device - T10255- or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Procedure
nform
ercia
Caution
m
at
om
io
If the intermediate gear wheel bolt was loosened, the drive gear
n
c
in t
or
wheel on the crankshaft was renewed or the crankshaft was

his
te
removed, a new intermediate gear wheel with coating must be

a
do
riv
installed and the hub ⇒ Item 15 (page 123) with bolt

p
cum
or
⇒ Item 14 (page 123) and thrust washers must be renewed.

f
en
ng
t.
yi
Otherwise, the tooth backlash will be incorrect. Procedure
Co
op py
when installing ⇒ page 133 .
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Lock balance shaft with locking tool - T10255- ; if necessary,

turn balance shaft.
• Locking tool pin must engage in groove in balancer shaft when
doing this.
– Insert dowel sleeves if no dowel sleeves for centring balance
shaft module are fitted on cylinder block.
– Place balancer shaft module on cylinder block.
• The intermediate gear wheel must mesh in the crankshaft spur
gear when the balance shaft is locked.
• The intermediate gear wheel must have a slight tooth back‐
lash. AG. Volkswagen AG d
agen oes
– Tighten bolts for balance shaft module: olksw not
y V gu
d b ara
se nte
thori
eo
⇒ page 125 s au ra
c
s
ce
le
un
pt
⇒ page 125
an
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– Remove crankshaft stop - T10050- .
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, is n
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hole
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– Install vibration damper.
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Sharan 2011 ➤
3 Oil filter bracket and engine oil cooler

⇒ “3.1 Assembly overview - oil filter bracket and engine oil cooler”,
page 137
⇒ “3.2 Removing and installing oil filter bracket with engine oil
cooler”, page 138
⇒ “3.3 Removing and installing oil pressure switch F1 ”,
page 141
⇒ “3.4 Checking oil pressure switch F1 ”, page 142
⇒ “3.5 Checking oil pressure”, page 143
3.1 Assembly overview

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. Vofilter bracket
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3 - O-ring
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❑ Renew
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4 - O-ring
t to the co
❑ Renew
5 - Oil filter element
rrectne
❑ Observe notes
⇒ page 122
❑ Removing and installing ss o
cial p
⇒ Maintenance ; Book‐
f in
let 808
form
mer
atio
6 - Engine oil cooler

om
n
c
❑ Observe notes
i
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⇒ page 122
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⇒ page 149
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❑ Renew coolant after re‐ Prote AG.
placing
7 - 11 Nm
8 - Seals
❑ Renew
9 - Bolt
❑ Renew
❑ Specified torque and
tightening sequence
⇒ page 138
10 - Oil filter bracket
❑ With integrated oil retention valve.
⇒ “3.2 Removing and installing oil filter bracket with engine oil cooler”, page 138
3. Oil filter bracket and engine oil cooler 137

Sharan 2011 ➤
11 - Seals
❑ Renew
Oil filter bracket - specified torques and sequence
Note
Renew oil filter bracket bolts.
– First tighten upper left and lower right bolts.

1) -Arrows- In diagonal sequence to 14 Nm
2) -Arrows- turn 90° further diagonally
3.2 Removing and installing oil filter bracket

with engine oil cooler
♦ Release lever - 80 - 200-
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♦ Used oil collector and extractor - V.A.G 1782-

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Sharan 2011 ➤
♦ Spring-type clip pliers - VAS 6362-
Removing
– Remove radiator cowl ⇒ page 150 .
olkswagen AG
en AG. V
– Remove oil filter element ⇒ Maintenance
olks
wag ; Booklet . does
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Sharan 2011 ➤

– Free off coolant hose -3-.
- G31- / intake air temperature sender - G42- and remove right
air pipe.
– Pull out oil dipstick slightly, unscrew bolt -1-.

– Press off clip -2- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side.
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Sharan 2011 ➤
– Place drip tray for workshop hoist - VAS 6208- under point of
separation.
– Remove coolant hoses. To do this, loosen hose clips -1-.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
⇒ “3.1 Assembly overview - oil filter bracket and engine oil
cooler”, page 137 .
Note
♦ Renew gaskets, seals and O-rings.

♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the same type of hose clips
as original equipment ⇒ Electronic parts catalogue .
– Install dipstick guide tube ⇒ page 122 .

– Install charge air pipe ⇒ page 218 .
– Installing intake hoses with screw-type clips ⇒ page 218 .
– Install air filter housing ⇒ page 263 .
– Install radiator cowl ⇒ page 150 .
– Install oil filter element, replenish engine oil and check oil level
⇒ Maintenance ; Booklet . gen AG
. Volkswagen AG
d a oes
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– Replenish coolant in cooling system, changed bcoolant
yV
o
if engine gu
ara
oil cooler has been renewed ⇒ page 159or.ise nte
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s au ra
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3.3 Removing and installing oil pressure
s
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switch - F1-
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– Press release buttons and remove hose -1- for venting crank‐
es, in part or in w
case.
t to the co
– Move clear vacuum hoses -arrows-.

– Remove air pipe from air filter housing; release hose clip -3-
rrectness of i
for this.
l purpos
– Unscrew bolt -2-, swing air pipe with inlet connection to rear
and pull off from turbocharger.
nform
mercia
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ion
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141
AG.
3. Oil filter bracket and engine oil cooler
Sharan 2011 ➤
– Unscrew bolts -2- and -3-, remove engine lifting eyes -1-.
– Separate electrical connector -arrow-.
– Remove oil pressure switch - F1- .
Installing
⇒ “1.4 Assembly overview - cylinder head”, page 84 .
Install in reverse order of removal, observingwthe
agenfollowing.
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– Install vacuum line to exhaust gas recirculation cooler
rm
ab
pe
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⇒ page 224 .
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– Install intake pipe ⇒ page 205 .
h re
hole
spec
es, in part or in w
3.4 Checking oil pressure switch - F1-
t to the co
rrectness of i
♦ Oil pressure tester - V.A.G 1342-
l purpos
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♦ Voltage tester - V.A.G 1527B- cted agen
Prote AG.

Sharan 2011 ➤
♦ Adapter set - V.A.G 1594C-
Procedure
• Oil level OK.
• Engine oil temperature approx. 80°C.
– Remove oil pressure switch - F1- ⇒ page 141 .
– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch.
– Screw oil pressure switch - F1- -item 2- into hole in oil pressure
tester.
– Connect brown line -1- of oil pressure tester to earth (–).
olksw
– Connect voltage tester
swa
gen AG - V.A.G 1527B-
.V agen AG
doewith
s no
auxiliary cables
from auxiliary
by Volkmeasuring set - V.A.G 1594C- t gu to oil pressure
switchris-edF1- and battery positive (+). ara
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• LED
s a should not light up.
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If LED lights up now, renew oil pressure switch - F1- .

wit
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– Start engine.
spec
es, in part or in w
t to the co
Note
rrectness of i
Observe oil pressure tester and LED while starting, as switching

point of oil pressure switch may already be exceeded when start‐
l purpos
ing.
nform
ercia
• LED should light up at 0.3…0.6 bar.

m
at
– If LED does not light up, renew oil pressure switch - F1-
om
ion
⇒ page 141 .
c
in t
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3.5 Checking oil pressure

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Prote AG.

Sharan 2011 ➤
♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK.
• Engine oil temperature approx. 80°C.
– Remove oil pressure switch - F1- ⇒ page 141 .
– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch - F1- .
– Screw an old oil pressure switch into hole on oil pressure tester
- V.A.G 1342- to seal hole.
– Start engine.
• Minimum oil pressure at idling speed: 0.6 bar. AG. Volkswagen AG d
agen oes
olksw not
• Minimum oil pressure at 2,000 rpm: 1.0 bar. d byV gu
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Prote AG.

Sharan 2011 ➤
19 – Cooling
1 Parts of cooling system
WARNING

restored.
hot components.
Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Test for leaks in cooling system using cooling system tester -

V.A.G 1274/- and adapter for expansion tank - V.A.G 1274/8- and
adapter for sealing cap - V.A.Ge1274/9- .
n AG. Volkswagen AG ag does
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⇒ “1.1 Assembly overview
y V - parts of cooling system, body
ol ot g side”,
ua
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page 145 ris
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⇒ “1.2 Assemblyau overview - parts of cooling system, engine side”,r ac
ss
page 147
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⇒ “1.3 Assembly overview - coolant pump and thermostat”, page

itte
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⇒ “1.4 Coolant hose connection diagram”, page 149

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1.1 Assembly overview - parts of cooling system, body side

ole,
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mer
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1. Parts of cooling system 145

Sharan 2011 ➤
1 - Radiator/cooler
⇒ page 151
❑ After renewing, renew
entire coolant.
2 - O-ring
❑ Renew if damaged
3 - Upper coolant hose
coolant hoses
⇒ page 149
4 - Cap
❑ Check using cooling
system tester -
V.A.G 1274- and adapt‐
er - V.A.G 1274/9-
⇒ page 174 .
5 - Connector
6 - 5 Nm
7 - Expansion tank
❑ Checking cooling sys‐
tem for leaks with cool‐
ing system tester -
V.A.G 1274- and adapt‐
er - V.A.G 1274/8-
⇒ page 174
8 - Lower coolant hose
coolant hoses
⇒ page 149 AG. Volkswagen AG d
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11 - Radiator fan - V7- s
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12 - Right radiator fan - V35- pt

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13 - Connector
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14 - Radiator cowl
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hole
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es, in part or in w
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146 Rep. gr.19 - Cooling

Sharan 2011 ➤
1.2 Assembly overview - partswof cooling

agen
AG. Volkswasystem,
gen AG
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1 - Grommet ris
utho eo
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❑ Not sold separately ss c
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2 - Sleeve
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3 - 2.7 Nm
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4 - 40 Nm
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spec
5 - Bracket
t to the co
❑ For coolant circulation
pump 2 - V178-
rrectne
6 - Front coolant pipe
s
⇒ page 163
s o
cial p
f
7 - O-ring
inform
mer
❑ Renew
atio
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8 - 8 Nm
o
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9 - Right coolant pipe

t
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10 - O-ring
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❑ Renew
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temperature sender - G83-
AG.

⇒ page 173
13 - 9 Nm
14 - 9 Nm
15 - 9 Nm
16 - Coolant line
17 - Seal
❑ Renew
18 - Union
❑ For coolant hoses
19 - O-ring
❑ Renew
20 - Radiator outlet coolant - G62-
21 - Double stud 9 Nm
❑
22 - 9 Nm
23 - Retaining clip
24 - Left coolant pipe

Sharan 2011 ➤
25 - 9 Nm
26 - 9 Nm
27 - 9 Nm
28 - 13 Nm
29 - Upper front coolant pipe
30 - Coolant circulation pump 2 - V178-
Volkswa AG. gen AG
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au
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1 - Coolant pump
an
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⇒ page 152
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2 - 15 Nm
h re
hole
spec
3 - O-ring
es, in part or in w
❑ Renew
t to the co
4 - O-ring
❑ Renew
rrectness of i
5 - 4/2-way valve with thermo‐
l purpos
stat
❑ The thermostat is loca‐
nform
ercia
ted within the 4/2-way

m
valve and cannot be ex‐

a
com
ti
changed individually.
on in
r
te o

thi
s
iva
⇒ page 154
do
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6 - 15 Nm
en
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Prote AG.

Sharan 2011 ➤
1.4 Coolant hose connection diagram
1 - Radiator for engine coolant

❑ Renew coolant after re‐
placing
2 - Coolant circulation pump 2
- V178-
3 - Engine oil cooler
4 - 4/2-way valve with thermo‐
stat
⇒ page 154
5 - Coolant pump
6 - Cylinder head and cylinder
block AG. Volkswagen AG d
agen oes
ksw
❑ Renew coolant after re‐ byV
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7 - Coolant expansion tank ss a ra
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❑ With cap
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❑ Checking pressure re‐

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lief valve in filler cap
rm
ab
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⇒ page 174 .
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8 - Exhaust gas recirculation
h re
hole
cooler
spec
es, in part or in w
❑ Checking exhaust gas
t to the co
recirculation cooler for
leaks ⇒ page 308
9 - Auxiliary heater
rrectness of i
10 - Circulation pump - V55-
l purpos
11 - Heat exchanger for heater

nform
ercia
12 - Gear oil cooler

m
❑ For double clutch gear‐

com
tio
box.
n in
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Prote AG.

Sharan 2011 ➤
2 Repairing cooling system

⇒ “2.1 Removing and installing cowling together with radiator fan
V7 and radiator fan on right of radiator V35 ”, page 150. Volkswage
n AG n AG d
wage oes
⇒ “2.2 Removing and installing radiator”, page
yV
olks151 not
gu
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⇒ “2.3 Removing and installing coolant
ho pump”, page 152
ris nte
eo
t
au ra
⇒ “2.4 Removing and installing 4/2-way
ss valve with thermostat”, c
page 154
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un
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an
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⇒ “2.5 Draining and adding coolant”, page 159
y li
erm
ab
ility
⇒ “2.6 Coolant pipes, coolant temperature sender”, page 163
ot p
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⇒ “2.7 Checking cooling system for leaks”, page 174
h re
ole,
spec
2.1 Removing and installing cowling togeth‐
t to the co
er with radiator fan - V7- and radiator fan
on right of radiator - V35-
rrectne
Removing
s
s o
cial p
f i
– Remove air filter housing with air mass meter and connecting
nform
pipe ⇒ page 263 .
mer
atio
m
– Unscrew upper bolts -upper arrows- of air cowling.

o
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c
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Rep. gr. 50 ; Body - front; Assembly overview - noise insulation

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– Remove connecting hose »hot side« to charge air pipe. To do

this, loosen hose clamps -1- and -2-.

AG. Volkswagen AG d
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ho eo
4-cylinder
aut common rail engine (2.0 l, EA189 Gen II) - Edition ra
c
10.2018
ss
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– Disconnect connector -1-.
un
pt
an
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– Unscrew lower bolts -lower arrows-.
rm
ab
pe
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– Remove cowling together with radiator fans downwards.
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– Thread out electrical connector -1- (if fitted) -2-. Move wiring
nform
ercia
clear.
m
a
com
t
– Unscrew nuts -arrows- and remove radiator fan.
ion in
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te o
Installing
thi
s
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do
Install in reverse order of removal.
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2.2 Removing and installing radiator

Rep. gr. 50 ; Noise insulation .
– Place drip tray - VAS 6208- beneath engine.
– Disconnect coolant hose -1- from radiator (right) and drain off
coolant.
– Pull off coolant hose -arrow- from radiator (left) and allow cool‐
ant to drain.
– Remove radiator cowl ⇒ page 150 .
2. Repairing cooling system 151

Sharan 2011 ➤
– Unscrew air duct on lock carrier -arrows-.
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– Unscrew bolts -1 and 2-.
, is n
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es, in part or in w
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l purpos
nform
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at
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– Unscrew securing bolt -arrow- for coolant pipes.

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Pull radiator »away« from coolant pipe bracket when unscrewing yri
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Prote AG.
– Remove radiator upwards.

Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Add coolant ⇒ page 159 .
2.3 Removing and installing coolant pump

Sharan 2011 ➤

equipment required
AG. Volkswagen AG d
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♦ Refractometer - T10007- yri
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Prote AG.
♦ Hose clamp pliers - VAS 6340-

Removing
Note
Renew gaskets and seals.


AG. Volkswagen AG d
agen oes
olksw not
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ed
ris nte
Sharan 2011 ut
h ➤
o eo
ra
a
4-cylinder
s common rail engine (2.0 l, EA189 Gen II) - Editionc
s 10.2018
ce
e
nl
pt
du
– Remove securing bolts -1- for coolant pump -2- and carefully
an
itte
y li
remove coolant pump.
erm
ab
ility
ot p
Installing
wit
, is n
h re
hole
spec
note the following:
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Moisten new O-ring -3- with coolant.
orm
m
atio
– Insert coolant pump -2- in cylinder block, and tighten securing
om
n in
bolts -1- to 15 Nm.
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
The coolant pump plug faces downwards. C py
ht. rig
rig ht
py by
co Vo
– Install toothed belt ⇒ page 77 .
by lksw
cted agen
Prote AG.
– Install poly V-belt ⇒ page 27 .
2.4 Removing and installing 4/2-way valve

with thermostat
Note
The thermostat is located within the 4/2-way valve and cannot be

renew individually.

Sharan 2011 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ 10 mm jointed spanner - 3185-

♦ Refractometer - T10007-
♦ Torx bit - T10058-
Removing
Note
Renew gaskets and seals.

– Remove air filter housing together with air mass meter and
connecting pipe ⇒ page 263 .
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .

Sharan 2011 ➤
– Remove battery carrier, unscrew securing bolts -arrows- for

this.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
er. Press release tabs to do this.
es, in part or in w
t to the co
– Free vacuum hoses -arrows- at air pipe.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
and remove from turbocharger.

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unclip wiring harness from bracket -arrow-.

Sharan 2011 ➤

bracket.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Unscrew bolts -2, 5- and -arrows-.
wit
, is n
h re
– Free electrical lines and hoses on left air pipe using removal
hole
spec
lever - 80 - 200- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Pull off coolant hoses. To do this, open hose clips -1-.
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove electrical connector -1- for Hall sender - G40- from

bracket.
– Unscrew bolts -arrows- and pull front coolant pipe to side away
from 4/2-way valve.

Sharan 2011 ➤
– Pull coolant pipe out of connection -C- for 4/2-way valve.

Leave in its installation position.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Free coolant hose -3-.
spec
t to the co
- G31- / intake air temperature sender - G42- and remove right
rrectne
air pipe.
– Remove alternator ⇒ starter, current supply, CCS; Rep. gr.
ss
27 ; Removing and installing alternator .
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Unscrew bolt -1-. Prote AG.
– Press off clip -2- using removal lever - 80 - 200- .

– Pull oil dipstick guide tube upwards out of cylinder block and
press aside.

Sharan 2011 ➤
– Pull coolant hoses off connections -A, B and D-.

– Remove securing bolts -3- for 4/2-way valve -2-.
– Pull valve out from cylinder block.
2.5 Draining and adding coolant

equipment required
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Refractometer - T10007-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-

Sharan 2011 ➤
2.5.1 Draining
WARNING
lkswage es n
Hot steam may escape when d by V expansion tank is opened. Cover
o ot g
ua
sealing cap with a cloth ir seand open it carefully.
ran
o tee
th or
au ac
ss
ce
le
– Open cap on coolant expansion tank.

un
pt
an
d
itte
y li
Remove noise insulation: ⇒ General body repairs, exterior; Rep.
rm
ab
gr. 50 ; Body - front; Assembly overview - noise insulation
pe
ility
ot
wit
, is n
– Pull coolant hoses -1- off coolant circulation pump 2 - V178-
h re
-2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
– Remove air hose. Release hose clips -1- and -2- for this. thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull off lower coolant hose retaining clip -arrow- and remove
coolant hose from quick-release connection of radiator.

Sharan 2011 ➤
– To drain coolant from engine, also remove coolant hose from

engine oil cooler -arrow-.
Note
lkswage es n
o ot g
Please observe disposal instructions! d byV ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
2.5.2 Filling
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
AG. Volkswagen AG d
agen oes
♦ Because of its high boiling point, the coolant improves engine Volksw not
gu
by
reliability under heavy loads, particularly in countries with trop‐ised ara
nte
ical climates. ut
hor eo
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♦ ONLY refractometer - T10007A- may be used for determining s
ce
e
current anti-freeze value.

nl
pt
du
an
itte
y li
♦ Frost protection must be guaranteed down to -25°C as a min‐
erm
ab
imum and, in countries with arctic conditions, down to approx.
ility
ot p
-36°C. Increasing the frost protection is permissible only if cli‐
wit
, is n
matic conditions require stronger frost protection. It may, how‐
h re
ever, be increased only to a maximum of -48°C. Otherwise,
hole
spec
the cooling effect will be impaired.
es, in part or in w
t to the co
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
rrectness of i
♦ Read off anti-freeze figures for respective replenished coolant
l purpos
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
nform
ercia
sponds the »ice flocculation point«. Flakes of ice may start

forming in the coolant below this temperature.
m
at
om
♦ Never reuse old coolant. ion

c
in t
or
his
te
♦ Use only a water/coolant additive mixture as a slip agent for

a
do
riv
coolant hoses.
p
cum
for
en
ng
t.
yi Co
Recommended mixing ratios (use only distilled water for mixing): Cop py
t. rig
gh ht
yri by
Frost Anti-freeze Coolant ad‐ Distilled wa‐
op Vo
by c lksw
protection to proportion ditive 1) ter 1)
cted agen
Prote AG.
-25°C 40% 3.2 l 4.8 l

-36°C 50% 4.0 l 4.0 l
1)The quantity of coolant can vary depending on the vehicle
equipment.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b
Sharan ara2011 ➤
nte
4-cylinder commonaut rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
ho eo
ra
ss c
ce
e
– Install lower coolant hose and secure with retaining clip
nl
pt
du
-arrow-.
an
itte
y li
erm
ab
– Connect coolant hoses to engine oil cooler and coolant circu‐
ility
ot p
lation pump 2 - V178- .
wit
, is n
h re
– Install noise insulation: ⇒ General body repairs, exterior; Rep.
hole
spec
gr. 50 ; Body - front; Assembly overview - sound insulation .
es, in part or in w
t to the co
With cooling system charge unit - VAS 6096- :
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
rrectness of i
– Fill coolant circuit using cooling system charge unit -
l purpos
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096.
nf
ercia
o
Without cooling system charge unit - VAS 6096- :
rm
m
atio
om
n in
– Slowly fill coolant to upper marking of shaded field on expan‐
or c
sion tank.
thi
te
sd
iva
o
r
– Fit expansion tank cap.

rp
cu
o
m
f
en
ng
– Start engine and maintain an engine speed of about 2,000 rpm

t.
yi Co
op
for about 3 minutes. C py
t. rig
gh ht
yri by
– Then run engine at idling speed until radiator fan cuts in. cop Vo
by lksw
cted agen
Prote
– Check coolant level and top up as needed. When engine is at
AG.
normal operating temperature, the coolant level must be at the

upper mark; when engine is cold, in the middle of the shaded
field.
2.6 Coolant pipes, coolant temperature

sender
⇒ “2.6.1 Removing and installing front coolant pipe”, page 163
⇒ “2.6.2 Removing and installing upper front coolant pipe”,
page 167
⇒ “2.6.3 Removing and installing left coolant pipe”, page 168
⇒ “2.6.4 Removing and installing right coolant pipe”, page 170
⇒ “2.6.5 Removing and installing coolant temperature sender G62
”, page 172
⇒ “2.6.6 Removing and installing radiator outlet coolant temper‐
ature sender G83 ”, page 173
2.6.1 Removing and installing front coolant

pipe

Sharan 2011 ➤
♦ Hose clamps, up to 25 mm - 3094- for vehicles with dual clutch

gearbox
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p

wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
Removing
thi
te
sd
va

i
o
pr
cum
r
fo

en
ng
t.
yi Co
op py
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Unscrew bolts -arrows- and remove battery mounting bracket

-1-.
er. Press release tabs to do this.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Free vacuum hoses -arrows- at air pipe.
rm
ab
pe
ility
ot
wit
, is n
and pull from turbocharger.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Unclip wiring harness from bracket -arrow-.

a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Clamp off coolant hoses using hose clamps -3094- and pull
from gearbox oil cooler. To do this, open hose clips -arrows-.

Sharan 2011 ➤

bracket.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
– Remove air hose. Release hose clips -1- and -2- for this.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
– Unscrew bolts -2, 5- and -arrows-.
rm
m
atio
m
– Free electrical wiring and hoses on left air pipe using removal
o
n in
c
lever - 80 - 200- .
or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release hose clips -1- and pull coolant hoses off.

Sharan 2011 ➤
– Remove electrical connector -1- for Hall sender - G40- from

bracket.
– Remove bracket from front from coolant pipe.
AG. Volkswagen AG d
– Open hose clips -2- and -3-, and pull coolant hoses off.
olks
wage
n oes
not
V gu
by
– Unscrew bolts -arrows- and pull front coolant pipe
ris out of 4/2-
ed
ara
nte
way valve. ut
ho eo
ra
a c
ss
Installing
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
♦ Renew gaskets, seals and O-rings.
rrectne
s
s o
cial p
f inform
– Clean or smoothen sealing surface for O-ring.
mer
atio
– Moisten O-ring with coolant and slide onto front coolant pipe.
om
n
c
i
or
n
– Push front coolant pipe into 4/2-way valve.
thi
te
sd
va
– Electrical connections and routing ⇒ Current flow diagrams,

i
o
pr
cum
r
Electrical fault finding and Fitting locations.

fo
en
ng
t.
yi Co
– Fill coolant system with coolant ⇒ page 159 . Cop py
t. rig
gh ht
pyri by
Vo
o
2.6.2 Removing and installing upper front
by c lksw
cted agen
Prote AG.
coolant pipe

Sharan 2011 ➤
Removing
AG. Volkswagen AG d
– Unscrew bolt -2-. lksw
agen oes
not
o
yV gu
– Open hose clips -1- and -3-, and pull coolant hoses off. rised b ara
nte
ho eo
– Remove upper front coolant pipe. aut ra
ss c
ce
e
Installing
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.6.3 Removing and installing left coolant pipe
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
♦ Hose clamps to 25 mm - 3094-

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Removing t. Cop py
rig
gh ht
– Remove noise insulation ⇒ Rep. gr. 50 . yri
p by
co Vo
by lksw
cted
agen
Prote AG.

bracket.

Sharan 2011 ➤
– Release hose clips -1- and -2- and remove air intake hose.
– Unscrew bolts -2-, -5- and -arrows-.

lever - 80 - 200- .
– Place drip tray for workshop hoist - VAS 6208- under engine.
– Clamp off coolant hoses with hose clamps -3094- and release
hose clips -1- and -4-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
– Pull coolant hoses off left coolant pipe.

nl
pt
du
an
itte
– Remove left coolant pipe.
y li
erm
ab
ility
Installing
ot p
wit
, is n
• Specified torques: ⇒ page 147
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nf
ercia
as original equipment ⇒ Electronic parts catalogue . orm

m
atio
om

n in
or c

thi
te
sd
iva

o
r
rp
cu
o
m
f
en
ng
t.
yi
2.6.4 Removing and installing right coolant
Co
Cop py
t. rig
pipe
gh ht
pyri by
Vo
o
by c lksw
cted agen
Special tools and workshop equipment required Prote AG.

Sharan 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
♦ Spring-type clip plierss a-u VAS 6362- ra
c
s ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform

mercia
– Unscrew bolts and nuts -arrows-.

a
com
tion in
– Move fuel filter clear to one side (fuel hoses remain connec‐
r
te o
thi
ted).
s
iva
do
r
rp
– Remove noise insulation ⇒ Rep. gr. 50 .

um
fo
en
ng
t.
– Remove front right wheel housing liner ⇒ Rep. gr. 66 .
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Place drip tray for workshop hoist - VAS 6208- under engine.
– Pull connector -3- off radiator outlet coolant temperature send‐
er - G83- .
– Clamp off coolant hoses with hose clamps -3094- .
– Release hose clips -arrows- and pull coolant hoses off right
coolant pipe.
– Unscrew nut -1- and bolt -2-, and remove right coolant pipe.
Installing
Note
Secure all hose connections with the same type of hose clips as
original equipment ⇒ Electronic parts catalogue .
– Fill coolant system with coolant ⇒ page 159 . AG. Volkswagen AG d

agen oes
olksw not
y V gu
2.6.5 Removing and installing coolant temper‐ d b ara
rise nte
o eo
ature sender - G62- th
au ra
ss c
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
Removing
atio
om
n in
c
• Engine cold.
or
thi
te
sd
a
– Briefly open filler cap for coolant expansion tank in order to

iv
o
r
rp
cu
reduce pressure in cooling system.

o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
– Remove noise insulation ⇒ Rep. gr. 50 . cted agen
Prote AG.

Sharan 2011 ➤

lever - 80 - 200- .
– Loosen hose clip -3- and press left air pipe with coolant pipe
aside.
– Pull connector -4- off coolant temperature sender - G62- .
Note
Place a cloth underneath connection toncatch

AG. Voescaping
lkswagen A coolant.
age G do
ksw es n
Vol ot g
– Pull off retaining clip -3-seand
d b pull coolant
y
temperature senderuaran
- G62- out of screw connection.
thori tee
or
au ac
Installing ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
Note
wit
is n
h re
ole,
♦ Renew O-ring.
spec
♦ Insert new coolant temperature sender - G62- immediately in‐ t to the co

to union to avoid loss of coolant. rrectne
– Check coolant level and top up if necessary ⇒ page 159 .

s
2.6.6 Removing and installing radiator outlet

s o
cial p
coolant temperature sender - G83-

inform
mer
atio
Removing
om
n
c
• Engine cold.
or
n thi
te
sd
a
– Briefly open filler cap for coolant expansion tank in order to

iv
o
pr
reduce pressure in cooling system.

um
r
fo
en
ng
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Co
Cop py
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Prote AG.

Sharan 2011 ➤
– Unscrew bolts and nuts -arrows-.

– Move fuel filter clear to one side (fuel hoses remain connec‐
ted).
– Pull connector -2- off radiator outlet coolant temperature send‐

er - G83- .
Note agen
AG. Volkswagen AG d
oes
olksw not
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by ara
Place a cloth underneath to catch escaping coolant. orised
nte
h eo
aut ra
s c
– Pull off retaining clip -1- and pull coolant temperature sender s
ce
e
nl
at radiator outlet - G83- out of screw connection of coolant
pt
du
an
pipe.
itte
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erm
ab
Installing
ility
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, is n
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hole
spec
es, in part or in w
Note
t to the co
♦ Renew O-ring.
rrectness of i
♦ Insert new radiator outlet coolant temperature sender - G83-
immediately into coolant pipe to avoid loss of coolant.
l purpos
– Check coolant level and top up if necessary ⇒ page 159 .
nform
mercia
at
2.7 Checking cooling system for leaks
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Prote AG.

Sharan 2011 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
an
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ab
ility
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wit
, is n
h re
♦ Cooling system tester - V.A.G 1274 B-

hole
spec
• Coolant temperature at least 40°C

es, in part or in w
t to the co
Note
rrectness of i
To perform the leakage test correctly, first run a self-test on the

l purpos
cooling system tester - V.A.G 1274 B- .

nf
ercia
orm
m
atio
om
n in
or c
thi
te
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t.
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Cop py
t. rig
gh ht
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Vo
co lksw
by
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Prote AG.

Sharan 2011 ➤
Self-test of cooling system tester - V.A.G 1274 B-

– Operate cooling system tester - V.A.G 1274 B- several times.
AG. Volkswagen AG d
agen oes
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d by ara
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un
pt
an
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ab
ility
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wit
– Build up a pressure of 3.0 bar on cooling system tester .
is n
h re
ole,
– Observe pressure on pressure gauge of cooling system tester
spec
for 30 seconds.
t to the co
If no pressure builds up or if the pressure drops again:
The cooling system tester - V.A.G 1274 B- is leaking and should
rrectne
not be used.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n
Checking cooling system for leaks
thi
te
sd
iva
– Unbolt coolant expansion tank -arrows- and tilt forwards slight‐
o
pr
cum
r
fo
ly.
en
ng
t.
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Cop py
t. rig
WARNING gh ht
pyri by
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On a warm engine, the cooling system is under high pressure. Prote AG.
Skin and other parts of the body may be scalded.
♦ Wear protective gloves.
♦ Wear protective goggles.
♦ Reduce excess pressure by covering cap of coolant ex‐
pansion tank with cloths and opening it carefully.
– Open cap -1- on coolant expansion tank.

Sharan 2011 ➤
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- to coolant expansion tank.
– Build up pressure of approx. 1.5 bar using hand pump of cool‐
ing system tester.
• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops by more than 0.2 bar, locate and rectify
leaks. agen
AG. Volkswagen AG d
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olks ot g
byV ua
ed ran
ris tee
Note tho or
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ss
The pressure drop of 0.2 bar within 10 minutes depends on the
ce
e
nl
pt
du
how far the coolant can cool down. The colder the engine, the
an
itte
lower the pressure drop.
y li
erm
ab
ility
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, is n
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WARNING
hole
spec
es, in part or in w
t to the co
Skin and other parts of the body may be scalded.
• Release pressure by pressing pressure relief valve on
rrectness of i
cooling system tester until the gauge shows a pressure of
l purpos
0.
nform
ercia
Check pressure relief valve in cap.

m
at
om
io
– Fit cooling system tester - V.A.G 1274 B- with adapter -

n
c
in t
or
V.A.G 1274/9- onto coolant filler cap.

his
ate
do
riv
– Using hand pump of cooling system tester, build up pressure

p
cum
or
and check the opening pressure of the filler cap.

f
en
ng
t.
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op
Colour of filler cap Opening pressure
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blue 1.4 … 1.6 bar
cop Vo
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black 1.6 … 1.8 bar
Prote AG.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.

Sharan 2011 ➤
20 – Fuel supply system n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
1 Safety regulations for working on fuel tho
ir se
d ran
tee
supply u or
a ac
ss
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un
pt
an
d
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WARNING
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spec
restored.
t to the co
hot components.
rrectne
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
ss o
♦ The fuel system is also under pressure! Before opening
cial p
f in
the system, wrap a cloth around the connection and care‐
form
mer
fully loosen to release the pressure!
atio
m
♦ Wear eye and hand protection when performing any type

o
n
c
i
or
n
of repair work on the fuel system!
thi
te
sd
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o
pr
cum
r
fo
When removing and installing fuel gauge sender or fuel pump
en
ng
t.
yi
(fuel delivery unit) from a full or partly full fuel tank, observe the
Co
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following:
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♦ Place the suction hose of an activated exhaust gas extraction
c by lksw
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system close to the assembly opening of the fuel tank to ex‐ Prote AG.
tract any fuel vapours that are released. If no exhaust gas
extraction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
178 Rep. gr.20 - Fuel supply system

Sharan 2011 ➤
2 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “6 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged ehoses
n AG. Vomust
lkswagbe renewed.
en AG
wag does
olks not
byV gu
ara
ed nte
ris
tho eo
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un
pt
an
d
itte
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
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Prote AG.
2. Rules for cleanliness 179

lkswage es n
Sharan 2011 ➤ byV
o ot g
ua
ed ra
4-cylinder common rail engine hor (2.0 l, EA189 Gen II) - Edition 10.2018 ntee
is
t or
au ac
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ce
le
3 Repair instructions if tank has been
un
pt
an
d
itte
filled with incorrect fuel
y li
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ab
pe
ility
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wit
, is n
Caution
h re
hole
spec
Irreversible damage to high-pressure components, especially
es, in part or in w
t to the co
the high-pressure pump due to lack of lubrication though diesel
can occur when filling fuel tank with incorrect fuel. Damage due
to seizure and metal particles can be expected. These metal
rrectness of i
particles will probably cause further damage to pressure reg‐
ulating valves and injectors.
l purpos
nform
ercia
Note
m
a
com
tion in
These instructions are intended to guide you through the individ‐
r
te o
thi
ual work steps by means of a flowchart, with various situations
s
iva
do
being taken into account.
r
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fo
en
ng
t.
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Was the engine started with the incorrect fuel?
Co
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Yes
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pyri by
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⇒ “3.1 Step 1 (Engine was started with incorrect fuel)”,
c by lksw
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page 180 Prote AG.
No
⇒ “3.2 Step 2 (Engine was not started with incorrect fuel)”,
page 181
3.1 Step 1 (Engine was started with incor‐

rect fuel)
– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 189

Sharan 2011 ➤
– Open plug-in connector -A- of fuel return line and pull line off.
n AG. Volkswagen A
ge G do
swa es
– Connect pressure
by
Vol
k
gauge pipe -VAS 6551/1-
not
to
gu the fuel return
ara
line coming
ris
e from the engine.
d
nte
tho eo
– Putss aopen
u
end of line -VAS 6551/1- into a suitable container.
ra
c
ce
le
– Connect vehicle diagnostic tester and then carry out guided

un
pt
an
function “Fuel pump activation”.
d
itte
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rm
ab
pe
ility
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Note
wit
, is n
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hole
spec
The fuel pump is now activated.
es, in part or in w
t to the co
– Repeat procedure, if necessary, until fuel tank is completely
empty.
rrectness of i
– Removing fuel tank ⇒ page 192
l purpos
– Remove fuel delivery unit ⇒ page 186 .

– Check fuel tank for metal particles.
nform
ercia
– Drain fuel pump reservoir of fuel delivery unit.

m
a
com
tio
– Carry out a visual inspection for foreign bodies and metal par‐
n in
r
te o
ticles in fuel pump reservoir and on preliminary filter.

thi
s
iva
do
Metal particles found?
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cum
fo
en
g
Yes
n
t.
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⇒ “3.3 Step 3 (There are filings in fuel delivery unit and fuel
Cop py
t. rig
tank)”, page 182
opyri
gh by
Vo
ht
c lksw
No
by
cted agen
Prote
⇒ “3.4 Step 4 (There are no filings in fuel delivery unit and fuel
AG.
tank)”, page 182
3.2 Step 2 (Engine was not started with in‐

correct fuel)
– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 189
– Open plug-in connector -A- of fuel return line and pull line off.
– Connect pressure gauge pipe -VAS 6551/1- to the fuel return
line coming from the engine.
– Put open end of line -VAS 6551/1- into a suitable container.
– Connect vehicle diagnostic tester and then carry out guided
function “Fuel pump activation”.
Note
– Repeat procedure, if necessary, until fuel tank is completely

empty.
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above.
3. Repair instructions if tank has been filled with incorrect fuel 181
Sharan 2011 ➤
– Reconnect fuel return line -A-.

– Renew fuel filter ⇒ Maintenance ; Booklet .
– Fill up vehicle and perform road test.
End
3.3 Step 3 (There are filings in fuel delivery

unit and fuel tank)
– Clean fuel delivery unit and fuel tank with diesel extractor -
VAS 5226- .
– Install fuel delivery unit ⇒ page 186 .
– Installing fuel tank ⇒ page 192
– Renew following high-pressure components:
♦ High-pressure pump ⇒ page 232 . n AG. Volkswagen AG do
lkswage es n
o ot g
♦ High-pressure lines ⇒ page 237 . d byV ua
ran
ir se tee
♦ Fuel rail including fuel pressure regulating
utho
valve - N276- and or
ac
a
fuel pressure sender - G247- ⇒ spage
s 237
ce
le
un
♦ Injectors (piezo injectors) ⇒ page 237

pt
an
d
itte
y li
♦ Fuel return lines (overflow oil lines) ⇒ page 237

rm
ab
pe
ility
♦ Fuel filter ⇒ Maintenance ; Booklet

ot
wit
, is n
h re
– Fill up vehicle.
hole
spec
– Bleed fuel system ⇒ page 235 .

es, in part or in w
t to the co
– Carry out road test.

End
rrectness of i
3.4 Step 4 (There are no filings in fuel deliv‐

l purpos
ery unit and fuel tank)

nform
ercia

m
a
com

ion in
r
te o
thi
s
iva
Caution
do
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rp
cum
fo
en
When the fuel metering valve - N290- is removed, there is the

ng
t.
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risk of damage to the high-pressure pump by the ingress of dirt . Cop py
from the outside. Scrupulous cleanliness must therefore be
t rig
gh ht
yri by
ensured. cop Vo
by lksw
cted agen
Prote AG.
– Carefully clean high-pressure pump in vicinity of fuel metering

valve - N290- .
– Detach connector from valve.

Sharan 2011 ➤
– Unscrew bolts -arrows- and carefully remove fuel metering

valve - N290- .
– Check fuel metering valve - N290- and high-pressure pump
for metal particles.
Metal particles found?
Yes
⇒ “3.5 Step 5 (There are filings in high-pressure pump)”, page
183
No
⇒ “3.6 Step 6 (There are no filings in high-pressure pump)”,
page 183 en AG. V
olkswagen AG
wag does
olks not
yV gu
3.5 Step 5 (There are filings in high-pres‐
b ara
ed nte
ris
ho eo
sure pump)
t
au ra
c
ss
ce
le
– Renew following high-pressure components:

un
pt
an
d
itte
y li
♦ High-pressure pump ⇒ page 232 .
erm
ab
ility
ot p
♦ High-pressure lines ⇒ page 237 .
wit
is n
h re
♦ Fuel rail including fuel pressure regulating valve - N276- and
ole,
fuel pressure sender - G247- ⇒ page 237
spec
t to the co
♦ Injectors (piezo injectors) ⇒ page 237
♦ Fuel return lines (overflow oil lines) ⇒ page 237
rrectne
♦ Fuel filter ⇒ Maintenance ; Booklet
– Fill up vehicle.
ss o
cial p
f inform
mer
– Carry out road test. atio

m
End
o
n
c
i
or
n thi
e
3.6 Step 6 (There are no filings in high-pres‐

t
sd
iva
o
r
sure pump)
p
cum
r
fo
en
ng
t.
yi Co
Cop py
Caution
t. rig
gh ht
pyri by
Vo
co lksw
by
Ensure that the oil seals of the fuel metering valve - N290- are
cted agen
Prote AG.
undamaged. If a seal is damaged, the high-pressure pump
must be renewed.
– Moisten lower seal of fuel metering valve - N290- with fuel.

– Slide valve into high-pressure pump while turning slightly.
– Screw in both bolts -arrows- finger-tight.
– First tighten bolts to 3 Nm, then tighten further to 7 Nm.
– Renew fuel filter ⇒ Maintenance ; Booklet .
– Fill up vehicle and perform road test.
End
3. Repair instructions if tank has been filled with incorrect fuel 183
Sharan 2011 ➤
4 Parts of fuel supply system

⇒ “4.1 Assembly overview - fuel tank”, page 184
⇒ “4.2 Assembly overview - fuel delivery unit, fuel gauge sender
and suction jet pump”, page 185
⇒ “4.3 Removing and installing fuel delivery unit”, page 186
⇒ “4.4 Removing and installing fuel gauge sender G ”,
page 188
⇒ “4.5 Emptying fuel tank”, page 189
⇒ “4.6 Removing and installing fuel tank”, page 192
4.1 Assembly overview - fuel tank
1 - Fuel tank filler neck

❑ With connection for
earth cable to body.
❑ Screw onto body to 10
Nm.
2 - Clamping washer
3 - Clip
4 - Heat shield
5 - 25 Nm
❑ Renew
6 - Fuel n AG. Volkswagen AG do
wage
❑ When removing, sup‐ olks es n
ot g
yV
port using engine and d b ua
ran
ir se
gearbox jack - V.A.G tho tee
or
1383 A- . ss
au ac
❑ Removing and installing ce
le
un
⇒ page 192 pt
an
d
itte
y li
erm
7 - Securing strap on left ab

ility
ot p

wit
is n
sition
h re
ole,

spec
t to the co
8 - Securing strap on right

sition
rrectne

s
9 - Metering pump - V54-

s o
cial p
❑ For auxiliary heater

inform
mer
10 - Fuel line
atio
m
❑ To metering pump -
o
n
c
V54-
i
or
n thi
te
sd
a
11 - Fuel delivery unit with fuel system pressurisation pump - G6-

iv
o
pr
cum
r
❑ With fuel gauge sender - G-

fo
en
ng
t.
yi
❑ Installation position of flange ⇒ page 185
Co
Cop py
t. rig
❑ Assembly overview - fuel delivery unit with suction-jet pump ⇒ page 185
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
❑ Checking fuel system pressurisation pump - G6- ⇒ page 196 .

Sharan 2011 ➤
12 - Fuel pump control unit - J538-

❑ To remove, first lower fuel tank.
13 - Locking ring 145 Nm
❑ Remove and install using wrench - T10202- .
Installation position of flange

• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
4.2 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet
pump swa
gen AG
. Volkswagen AG
does
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1 - Fuel line tho eo
au ra
❑ for metering pump s-s c
ce
e
V54-
nl
pt
du
an
itte
2 - Fuel return line y li

erm
ab
❑ blue ility
ot p
wit
❑ From fuel filter.
, is n
h re
hole

spec
es, in part or in w
3 - Fuel supply line

t to the co
❑ black
rrectness of i
4 - Connector
l purpos
❑ For fuel delivery unit.

5 - Connector
nf
ercia
or
❑ For fuel gauge sender -

m
m
atio
G-
om
n in
or c

thi
te
sd
a
❑ Remove and install us‐

iv
o
r
rp
cu
ing wrench - T10202- .

o
m
f
en
ng

t.
yi Co
Cop py
. rig
7 - Flange
ht ht
rig by
opy Vo
❑ For fuel delivery unit. by c lksw
cted agen
Prote AG.
❑ For fuel gauge sender -
G-
❑ Always renew flange
seal.
❑ Note installation posi‐
tion on fuel tank
⇒ page 185
4. Parts of fuel supply system 185

Sharan 2011 ➤
8 - Suction hose
❑ With suction-jet pump
❑ Clipped onto fuel tank.
9 - Fuel delivery unit with fuel system pressurisation pumpge- nG6-AG. Volkswagen AG d
swa oes
❑ Removing and installing ⇒ page 186 yV
olk not
gu
d b ara
❑ Checking fuel system pressurisation pump oris - G6- ⇒ page 196 .
e nte
eo
th
❑ Note installation position on fuel tank
ss
a ⇒ page 185
u ra
c
❑ With fuel gauge sender - G-
ce
le
un
pt
an
❑ Clean strainer if soiled d
itte
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rm
ab
10 - Seal
pe
ility
ot
wit
❑ Renew
, is n
h re
❑ When installing, fit dry in fuel tank opening.
hole
spec
❑ Moisten with fuel only when installing flange.
es, in part or in w
t to the co
11 - Fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 188
rrectness of i
l purpos
4.3 Removing and installing fuel delivery

unit
nform
mercia
a
com
tion in
Note
r
te o
thi
s
iva
do
After removing fuel delivery unit, check fuel tank for heavy soiling
r
rp
cum
fo
and clean if necessary.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
♦ Special wrench - T10202-
by lksw
cted agen
Prote AG.
♦ Torque wrench (40200 Nm) - V.A.G 1332-

Sharan 2011 ➤
Removing:
Caution
Condition:
• The fuel tank must not be more than 3/4 full. This ensures
that the fill level is below the flange of the fuel delivery unit.
Note
♦ Empty fuel tank if necessary ⇒ page 189 .

♦ Note safety precautions before beginning work ⇒ page 178 .
♦ Observe rules for cleanliness ⇒ page 179 .
♦ Assembly overview - fuel tank ⇒ page 184 .
– Remove fuel tank ⇒ page 192 .

– Pull fuel return line -1- and fuel supply line -4- off flange.
Note
Release connection by pressing button on hose coupling.

nA n AG d G. Volkswage
– Pull off fuel line -3- (if there is one) Vfor wage
olksmetering pump - V54- s not g
oe
for auxiliary heater. ed
by ua
ra
is nte
or eo
– Pull connectors -2- and -5-auoff
th flange. ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
– Open locking ring using wrench - T10202- and raise flange.

ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Pull off hose coupling -1-.
Note
– Unclip filler hose -2- out of fuel delivery unit housing.

– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
♦ If delivery unit is to be renewed, drain old delivery unit before

disposal.
♦ Observe disposal regulations!
Installing: . Volkswagen AG
gen AG does
swa
– Renew seal. y Volk not
gu
edb ara
is nte
– Insert seal forhor fuel delivery unit dry into opening of fuel tank.
eo
aut ra
– Coat inner
s side of seal with fuel.
s c
ce
le
un
pt
– When inserting fuel delivery unit, ensure that fuel gauge send‐
an
d
itte
er is not bent.
y li
erm
ab
ility
ot p
– Press sealing flange down against spring pressure, and move

wit
is n
sealing flange to installation position.

h re
ole,
spec
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
t to the co
• -Arrow- points in direction of travel.

rrectne
– Tighten sealing flange.

• Specified torque: 145 Nm
ss o
Further assembly is performed in the reverse order of removal.

cial p
f in
When doing this, observe the following:

form
mer
– Ensure push-fit couplings and electrical connectors are se‐

atio
om
cured properly by pulling.

n
c
i
or
n thi
te
sd
a
4.4 Removing and installing fuel gauge

iv
o
pr
cum
r
fo
sender - G-
en
ng
t.
yi Co
op py
Removing:
t. C rig
gh ht
pyri by
Vo
– Remove fuel delivery unit ⇒ page 186 .
o
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cted agen
Prote AG.
– Press together securing tabs -arrows- and pull off fuel gauge
sender upwards.
– Note colour co-ordination of cables for reinstallation.

Sharan 2011 ➤
– Release electrical connectors -1…3- and pull them off. Then

bend back locking lugs of connectors.
Installing:
– Connect plug connectors -1…3-. Observe colour. Vco-ordina‐

tion. AG olkswagen AG d
agen oes
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– Check connectors are secured properly
ise
db by pulling. ua
ran
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ho
– Insert fuel gauge sender - G-au into guide on fuel delivery unit
t or
ac
ss
and press down until it engages.
ce
le
un
pt
– Install fuel delivery unit ⇒ page 186 .
an
d
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4.5 Emptying fuel tank
rrectness of i
⇒ “4.5.1 Emptying fuel tank when fuel pump is defective”,
page 189
l purpos
⇒ “4.5.2 Emptying fuel tank when fuel pump is intact ”,

page 191
nform
ercia
4.5.1 Emptying fuel tank when fuel pump is

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♦ Fuel extractor - VAS 5190-

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Sharan 2011 ➤
♦ Not illustrated
♦ Torque wrench - V.A.G 1332- (40…200 Nm)
Procedure
– Note safety precautions before beginning work ⇒ page 178 .
– Observe rules for cleanliness ⇒ page 179 .
– Open tank flap.
– Mark the distance -a- = 770 mm from end of extraction hose
of fuel extractor - VAS 5190- , use insulating tape -arrow-.
Note
The extraction hose has been properly inserted when the affixed
mark is level with the edge of the filler neck.
– Push hose into fuel filler neck and extract fuel.

AG. Volkswagen AG d
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Note orised
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♦ When no more fuel is extracted, the tank is emptied just ss c
ce
le
enough for the sender flange to be opened without danger.

un
pt
The tank may be removed while containing remaining fuel.
an
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ab
♦ If work has to be done on fuel pump or fuel gauge sender -
ility
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G- , proceed as follows:
wit
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ole,
spec
– Lower fuel tank carefully until fuel return line -1- and fuel supply
line -2- can be pulled off flange ⇒ page 192 .
t to the co
Note
rrectne

ss o
cial p
f in
– Pull off fuel line -4- (if there is one) for metering pump - V54-
form
mer
for auxiliary heater.

atio
om
– Pull connectors -3- and -5- off flange.

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c
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or
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Cop py
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Prote AG.

Sharan 2011 ➤
– Open locking ring using wrench

agen
- .T10202-
AG Volkswage.n AG
do w es n
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– Raise flange of fuel
ed
bdelivery
yV unit. ua
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– Insert suctionauhose
tho of fuel extractor - VAS 5190- as far as e or a
possible into
ss fuel tank and extract fuel. c
ce
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nl
If fuel tank needs only to be emptied, install fuel delivery unit again
pt
du
an
itte
⇒ page 186 .
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For further work on inside of fuel tank, sender flanges may remain
ility
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removed.
wit
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hole
If fuel tank needs only to be emptied, install flange of fuel delivery
spec
unit again ⇒ page 186 .
es, in part or in w
t to the co
– Renew seals of sender flange.
rrectness of i
Note
l purpos
♦ Do not interchange supply and return lines (return line -1- blue,
nf
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supply line -2- black).
orm
m
atio
♦ Ensure that connectors and fuel hose connections are fitted
om
securely.
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Cop py
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4.5.2 Emptying fuel tank when fuel pump is

co Vo
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intact
Fuel extraction unit - VAS 5190-
Not illustrated
Hose - VAS 6550/1-
WARNING
Fuel supply line is pressurised. Wear protective goggles and

protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully loosening the
union nut.
– Pull off supply line -arrow- and catch escaping fuel with a cloth.

wage es n
Sharan 2011 ➤ yV
olks ot g
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4-cylinder common rail engine (2.0 l, EA189 Gen II) ir se- Edition 10.2018
d ran
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Note
pt
du
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Press in securing ring to release the fuel lines.
ility
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– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
h re
hole
tractor - VAS 5190 /3 - to fuel supply line.
spec
es, in part or in w
– Connect vehicle diagnostic tester and perform the guided
t to the co
function “Emptying fuel system”.
rrectness of i
Note
l purpos
nform
ercia
– Repeat procedure until fuel tank is completely empty.

m
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ion
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4.6 Removing and installing fuel tank
in t
or
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ate
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riv

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Prote AG.
♦ Engine and gearbox jack - V.A.G 1383 A-
4.6.1 Removing
– Note safety precautions before beginning work ⇒ page 178 .
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With the ignition switched off, disconnect battery earth strap.
– Open fuel flap and remove fuel tank cap.
– Remove tank flap: ⇒ General body repairs, exterior; Rep. gr.
55 .
– Drain fuel tank and clean fuel filler neck and surrounding area.

Sharan 2011 ➤
– Unbolt filler neck from body -arrows-.
WARNING
Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.
– Detach connector -1- for fuel pump control unit - J538- .

– Disconnect supply line -2- (black), return line -3- (blue) and (if
fitted) line leading to metering pump - V54- -4-.
Note
lkswage es n
– Unscrew securing by strap
Vo and securing bolts. Whenot doing
gu
ara this,
support fuel tank
oris with engine and gearbox jack - V.A.Gn1383
ed
tee
A- . aut
h or
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– Then, carefully lower the fuel tank further. While doing so,
ce
le
un
pt
guide through filler neck between rear axle and body.

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4.6.2 Installing
rrectne

note the following:
ss o
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♦ Do not interchange supply and return hose (return line -1- blue
inform
or blue markings, supply -2- black).

mer
atio
m
♦ Connections for breather and fuel lines must engage audibly

o
n
c
when joined.
i
or
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sd
♦ Clip fuel lines onto fuel tank.

iva
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♦ Install breather and fuel hoses free of kinks.

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♦ Ensure that connectors and fuel hose connections are fitted Cop py
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securely. gh ht
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♦ Check earth connection on fuel tank and body to filler neck. Prote
cted AG.
agen

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Sharan 2011 ut ➤
ho eo
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a
4-cylinder
s common rail engine (2.0 l, EA189 Gen II) - Editionc 10.2018
s
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un
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5 Repairing fuel supply
rm
ab
pe
ility
ot
⇒ “5.1 Assembly overview - fuel filter”, page 194
wit
, is n
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⇒ “5.2 Removing and installing fuel filter”, page 195
hole
spec
es, in part or in w
⇒ “5.3 Checking fuel system pressurisation pump G6 ”,
t to the co
page 196
⇒ “5.4 Assembly overview - accelerator mechanism”, page 200
rrectness of i
⇒ “5.5 Removing and installing accelerator pedal module”,
l purpos
page 201
5.1 Assembly overview - fuel filter
nform
mercia
a
com
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1 - Supply line
on in
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❑ From fuel tank
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2 - Supply line
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❑ To high-pressure pump
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3 - Return line
C py
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❑ From high-pressure
p by
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pump. Prote
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agen
4 - Bolt for upper part of fuel fil‐

ter
❑ 5 Nm
5 - Filter insert
6 - Lower part of fuel filter
7 - 10 Nm

Sharan 2011 ➤
5.2 Removing and installing fuel filter

Removing
– Open plug-in connectors -A- and -B- of fuel lines.
lkswage es n
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byV ua
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un
pt
– Unclip retainer for coolant hose -1-.
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Undo securing bolts and nuts -arrows-.

m
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tion in
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te o
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iva
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pyri by
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by
cted agen
Prote AG.
– Electrical connectors -1- and -3-, open clip -2- and pull off fuel
supply line.
5. Repairing fuel supply 195

Sharan 2011 ➤ . Volkswagen AG
gen AG d es
4-cylinder common rail engine (2.0Vl,olkEA189
swa Gen II) - Edition o10.2018
not
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– Pull fuel return hose -5- off fuel return
tho
r
line. eo
s au ra
c
– Remove fuel filter upwards. s
ce
le
un
pt
– Collect any escaping fuel.
an
d
itte
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rm
ab
Installing
pe
ility
ot
wit
, is n
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following:
hole
spec
♦ Rout fuel hoses free of kinks.
es, in part or in w
t to the co
♦ Do not interchange fuel supply and return lines (return line is
rrectness of i
blue or with blue markings and supply line is white or with white
markings).
l purpos
♦ Clip fuel and coolant hoses into retainers again.
nform
ercia

m
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tio
5.3 Checking fuel system pressurisation
n in
r
te o
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pump - G6-
s
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5.3.1 Checking delivery pressure and quantity
Co
Cop py
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for fuel system pressurisation pump -
gh ht
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by c
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Prote AG.

♦ Vehicle diagnostic tester
♦ Connecting nipple - VAS 6551/5-1-
♦ Hose - VAS 6551/2-
♦ Hose - VAS 6551/1-
♦ Pressure tester (diesel) - VAS 6551-
Test specification:
• Fuses must be OK.
• Connect battery charger to ensure sufficient voltage supply of
min. 12.5 V.
• Minimum filling level of fuel tank: 15 l.
• Ensure that vehicle is placed on a level surface.
• Ensure that fuel hoses and lines in engine compartment and
on underbody are not closed through damage (kinks).
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.

Sharan 2011 ➤
Note
The vehicle must be fuelled with the diesel fuel appropriate for thegen AG. Volkswagen AG d
time of the year. The fuel sold in summer can be filtered down Vol
ksw to
a oes
not
0°C; that sold in the autumn can be filtered down to -10°C d b and
y gu
ara
that sold in winter can be filtered down to -20°C. Summer rise fuel may nte
ho eo
coagulate (flock) at very low winter temperatures. s a If you are un‐
ut ra
c
sure, try and expose it to the low outside temperature
s for approx‐
ce
le
imately 1 hour. If the fuel coagulates at temperatures above -20°
un
pt
an
d
C, it is unsuitable for low temperatures. This coagulation can
itte
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block the strainer in the fuel delivery unit as well as the fuel filter.
rm
ab
pe
ility
ot
wit
, is n
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WARNING
hole
spec
es, in part or in w
Fuel supply line may be pressurised. Wear protective goggles
t to the co
and protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
rrectness of i
off connection.
l purpos
Test sequence for high-pressure pump
nform
ercia

m
a
com
tio
– Open clamp and pull fuel supply line -arrow- off the high-pres‐
n in
r
te o
sure pump.
thi
s
iva
do
– Place connecting nipple - VAS 6551/5-1- in supply line and
r
rp
cum
fo
secure with clamp.
en
ng
t.
yi Co
op
– Connect hose - VAS 6551/2- between connecting nipple - VAS C py
t. rig
6551/5-1- and connection point »A« of pressure tester (diesel) gh ht
yri by
- VAS 6551- . cop Vo
by lksw
cted agen
Prote AG.
– Connect hose - VAS 6551/1- to connection point »B« of pres‐
sure tester (diesel) - VAS 6551- .
– Guide open end of hose - VAS 6551/1- into a suitable meas‐
urement container.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.

Sharan 2011 ➤
– Open shut-off taps “A” and “B” of pressure tester - VAS 6551-
and close shut-off tap “C”.
– Connect vehicle diagnostic tester and then carry out “Guided
. Volkswagen AG
Fault Finding, Checking electrical fuel pump(s)”. swa
gen AG does
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Note tho eo
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The fuel pump will be activated for 30 seconds.
un
pt
an
d
itte
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rm
ab
– Carefully close shut-off tap “B” and set pressure of 4.5 ± 0.1
pe
ility
bar.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
If the specified pressure is not attained, carry out “test sequence
for fuel filter” ⇒ page 198 . Reason may be a blocked fuel filter.
rrectness of i
– After setting desired pressure, empty measurement container
l purpos
and carry out “Guided Fault Finding, Checking electrical fuel

pump(s)” again.
nform
ercia
– Observe pressure on pressure tester - VAS 6551- .

m
a
com
– After controlling pump (30 seconds), read supplied fuel quan‐
tion in
tity in measurement container. Specification: min. 1400 ml.
r
te o
thi
s
If the specifications are attained: fuel system pressurisation pump
iva
do
r
- G6- OK.
rp
cum
fo
en
ng
t.
If the specified value is not attained, carry out test sequence for op
yi Co
fuel filter ⇒ page 198 .
C py
ht. rig
rig ht
py by
Test sequence for fuel filter co Vo
by lksw
cted agen
Prote AG.
– Reconnect fuel supply line to high-pressure pump.
– Pull off fuel supply line -B-. To do this, press the quick-release
couplings onto the connections, press in the locking elements
(keep pressed) and pull the quick-release couplings off.
– Connect hose - VAS 6551/2- between fuel line from fuel tank
and connection point “A” of pressure tester - VAS 6551- .
– Connect hose - VAS 6551/1- to connection point “B” of pres‐
urement container.
button.

Sharan 2011 ➤
Fault Finding, Checking electrical fuel pump(s)”.
Note
– Carefully close shut-off tap “B” and set pressure of 4.5 ± 0.1
bar.
Note
If the specified pressure is not attained, carry out “test sequence

on fuel filter” ⇒ page 199 . Reason: fuel line may be pinched or
kinked.
– After setting desired pressure, empty measurement container

and carry out “Guided Fault Finding, Checking electrical fuel
pump(s)” again.
- G6- OK, renew fuel filter element. ⇒ Maintenance ; Booklet
If the specified value is not attained, carry
ge out
n AG. Volkstest
wagesequence
n AG d
oes on
swa
fuel filter ⇒ page 199 . y Volk not
gu b ara
ed
Test sequence on fuelthtank
or
is nte
e or
au ac
ss
– Pull fuel supply line (black or black marking) -2- off fuel tank.
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
ot p
wit
, is n
Press in securing ring to release the fuel lines.

h re
hole
spec
es, in part or in w
– Collect escaping fuel with a cleaning cloth.

t to the co
– Connect hose - VAS 6551/2- between fuel line and connection

point “A” of pressure tester - VAS 6551- .
rrectness of i
– Connect hose - VAS 6551/1- to connection point “B” of pres‐

l purpos

nf
ercia
urement container.
orm
m

atio
om
button.
n in
or c
thi
te
sd
iva
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f
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
Fault Finding, Checking electrical fuel pump(s)”.
Note

olkswagen AG
en AG. V
– Carefully close shut-offotap
ksw “B” and set pressure of
ag does
n4.5
ot g ± 0.1
V l
bar. ed by ua
ra
ris nte
tho
– After setting desired pressure, empty measurement container eo
au ra
and carry out
ss “Guided Fault Finding, Checking electrical fuel c
pump(s)” again.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
- G6- OK., check that fuel line to engine is not kinked or crushed
es, in part or in w
and renew as necessary.
t to the co
5.4 Assembly overview - accelerator mechanism
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
1 - Connector
❑ Black, 6-pin.
2 - Gas pedal module
❑ With accelerator posi‐
tion sender - G79- and
accelerator position
sender 2 - G185-
❑ Not adjustable.
❑ The accelerator position
sender passes the posi‐
tion of the accelerator AG. Volkswagen AG d
on to the engine control agen oes
olksw not
V
unit. ed by gu
ara
ris nte
❑ Removing and installing ut
ho eo
ra
⇒ page 201 ss a c
ce
le
❑ -A-: apertures for re‐

un
pt
lease tool
an
d
itte
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rm
ab
3 - 10 Nm
pe
ility
ot
wit
4 - Cover
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t.
5.5 Removing and installing accelerator
rig
gh ht
pyri by
Vo
o
pedal module
by c lksw
cted agen
Prote AG.

♦ Release tool - T10238-

Sharan 2011 ➤
For right-hand drive:
♦ Release tool - T10240-

Removing
– Remove steering column cover -arrows-.
– Prise out cap -3- using a screwdriver.
– Remove bolts -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
– Release connector -1- and pull it off accelerator module.

an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
– Push release tool - T10238- (for right-hand drive vehicles re‐
yi Co
op py
lease tool - T10240- ) into intended holes as shown to stop t. C rig
gh ht
and remove accelerator module. yri
p by
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by c lksw
cted
Installing
agen
Prote AG.

Sharan 2011 ➤
– Reconnect connector -1- to accelerator module -4-. Lock con‐

nector -arrow-.
– Press accelerator module onto securing pins -5-.
– Insert centring pin -6- into hole in vehicle floor.
– Secure accelerator module with bolt -2- and install cap -3-.
– Install steering column trim.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
21 – Turbocharging/supercharging
1 Exhaust turbocharger
⇒ “1.1 Safety precautions”, page 204
⇒ “1.2 Rules for cleanliness”, page 204
⇒ “1.3 Assembly overview - turbocharger”, page 205
⇒ “1.4 Removing and installing turbocharger”, page 207
⇒ “1.5 Replacing vacuum unit with position sender for charge
pressure positioner G581 ”, page 211
WARNING

♦ Route lines of any kind so that the original routing can be AG. Volkswagen AG d
agen oes
ksw
restored. by
Vol not
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ara
ed
is nte
♦ Ensure that there is sufficient clearance to all movingthor
or eo
hot components. ss au ra
c
ce
le
un
pt
an
d
itte
Note the following if testers and measuring instruments have to
y li
erm
ab
be used during a road test:
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♦ Test equipment must always be secured on the rear seat and
is n
h re
operated by a 2nd person.
ole,
spec
If test and measuring instruments are operated from front pas‐
t to the co
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
rrectne
1.2 Rules for cleanliness
ss o
cial p
f
Caution
inform
mer
If a mechanical fault is found on the turbocharger, e.g. a de‐ atio

m
stroyed compressor impeller, just renewing the turbocharger is

o
n
c
i
or
not enough. To prevent this from causing further damage, per‐

thi
e
form the following repairs:

t
sd
iva
o
pr
cum
♦ Check air filter housing, air filter element and intake hoses
r
fo
en
ng
for soiling.
t.
yi Co
Cop py
♦ Check complete charged air routing and charge air cooler
t. rig
gh ht
yri
for foreign objects.
p by
o Vo
by c lksw
cted agen
If foreign objects are found in the charge air system, the charg‐
Prote AG.
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
When working on the turbocharger, pay careful attention to the

following rules for cleanliness:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
204 Rep. gr.21 - Turbocharging/supercharging

Sharan 2011 ➤
olksw
(2.0 l, EA189 Gen II) - Edition 10.2018
AG. V agen AG
agen does
lksw not
♦ Carefully cover opened components or db
yseal
Vo
them if repairs gu
ara
cannot be carried out immediately.orise nte
h eo
ut ra
♦ Install clean components only.ss Do not remove replacement
a c
ce
le
un
pt
an
d
itte
toolboxes).
y li
rm
ab
pe
ility
♦ Transportation and protective packaging and sealing caps
ot
wit
must be removed only immediately before fitting. , is n
h re
hole
♦ When making repairs, remove oil from connection and hose
spec
ends.
es, in part or in w
t to the co
move the vehicle.
rrectness of i
1.3 Assembly overview - turbocharger
l purpos
Note
nform
mercia
♦ All hose connections are secured.
a
com
tion in
♦ Charge air system must be free of leaks.
r
te o
thi
s
iva
♦ Renew self-locking nuts.
do
r
rp
cum
fo
♦ Before screwing on oil supply line, fill turbocharger at connec‐
en
ng
t.
yi
tion with engine oil.
Co
Cop py
t. rig
gh
♦ After installing turbocharger, run engine for about 1 minute at
ht
pyri by
idling speed to ensure that oil is supplied to turbocharger.
o Vo
by c lksw
cted agen
Prote AG.
1. Exhaust turbocharger 205

Sharan 2011 ➤

pipe
❑ With flexible joint; do not
bend flexible joint - risk
of cracking
2 - Seal
❑ Renew
3 - 17 Nm lkswage es n
o ot g
❑ Renew byV ua
d ran
ir se tee
o
4 - Oil supply line auth or
ac
ss
❑ Check for continuity.
ce
le
un
pt
❑ Before installing, fill tur‐
an
d
itte
y li
bocharger with engine
erm
ab
oil at oil supply line con‐
ility
ot p
nection.
wit
is n
h re
❑ Tighten union nuts to 22
ole,
Nm.
spec
5 - Oil return line
t to the co
6 - Seal
❑ Renew
rrectne
7 - 24 Nm
ss o
8 - Heat shield
cial p
f inform
9 - Exhaust turbocharger
mer
atio
❑ Can only be renewed
om
complete with exhaust
n
c
i
or
n
manifold and vacuum
thi
te
sd
a
unit.
iv
o
pr
cum
r
fo
en
ng
⇒ page 207
t.
yi Co
Cop py
10 - Retaining ring
t. rig
gh ht
pyri by
❑ Installation possible in
co Vo
by lksw
cted
one position only.
agen
Prote AG.
11 - O-ring
❑ Renew
12 - Pulsation damper
13 - 9 Nm
14 - Intake connecting pipe
15 - 9 Nm
❑ Attached in inlet connection.
16 - O-ring
❑ Renew
17 - Bracket
18 - 15 Nm
19 - Heat shield
20 - Seal
❑ Renew
21 - 24 Nm
❑ Renew

Sharan 2011 ➤
22 - Exhaust gas temperature sender 1 - G235-

❑ Assembly overview ⇒ page 285
23 - 20 Nm
24 - Support
❑ For turbocharger
25 - 9 Nm
26 - O-ring
❑ Various diameters.
AG. Volkswagen AG d
❑ Renew agen oes
olksw not
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27 - Banjo bolt; 40 Nmorise nte
th eo
u ra
28 - O-ring ss a c
ce
e
❑ Renew
nl
pt
du
an
itte
29 - Banjo bolt; 30 Nm
y li
erm
ab
ility
30 - O-ring
ot p
wit
, is n
❑ Renew
h re
hole
spec
31 - 24 Nm
es, in part or in w
t to the co
1.4 Removing and installing turbocharger
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Note
Fit heat shield sleeve in the same place when installing.
– Observe rules for cleanliness ⇒ page 204 .

lkswage es n
o ot g
byV ua
d ran
Sharan 2011 ➤ ho
ir se tee
t or
4-cylinder common rail engine (2.0 l,s EA189
au Gen II) - Edition 10.2018 ac
s
ce
le
un
pt
an
d
itte
Caution
y li
rm
ab
pe
ility
If a mechanical fault is discovered on the turbocharger (e.g. a
ot
wit
, is n
destroyed compressor impeller), it is not sufficient to just renew
h re
the turbocharger. To avoid any subsequent damage, the fol‐
hole
spec
lowing work must be carried out:
es, in part or in w
t to the co
♦ Check air filter housing, air filter element and air inlet ho‐
ses for contamination.
rrectness of i
♦ Check the whole charge air path and charge air cooler for
foreign objects.
l purpos
♦ If foreign objects are discovered in the charge air system,

clean the charge air path and, if necessary, renew the
nform
ercia
charge air cooler.

m
a
com
tion in
– Remove particulate filter ⇒ page 274 .
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
er. To do this, press release buttons.
Co
Cop py
t. rig
gh
– Expose vacuum hoses -arrows- at air pipe.
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
– Remove heat-shield sleeve.
– Pull vacuum hose -2- off turbocharger vacuum unit.
– Separate vacuum hose -3-.
– Disconnect electrical connector -1- at position sender for

charge pressure positioner - G581- .
– Free electrical connector -1- for exhaust temperature sender

1 - G235- and electrical line.

Sharan 2011 ➤

– Loosen hose clip -1- and remove pulsation damper -2-.
olksw
– Unscrew bolts andageremove
n AG. V pipes -A- dfor
agen AG
oesexhaust gas recircu‐
ksw
lation. by Vol not
gu
d ara
se n
– In vehicles
tho
ri with an auxiliary heater, remove the brackets
tee
or for
thes aucoolant lines leading to the auxiliary heater from the
ac cylin‐
der
s
block or transfer gearbox and the oil sump.
ce
e
nl
pt
du
Vehicles with front-wheel drive
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
remove turbocharger support with oil supply line.
rrectness of i
Vehicles with all-wheel drive

l purpos
– Removing and installing drive shaft ⇒ Running gear, axles,

steering; Rep. gr. 40 .
nf
ercia
orm
– Pull right flange shaft from bevel box ⇒ final drive, axle differ‐
m
atio
m
ential; Rep. gr. 39 .

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t.
– Unscrew bolts -1- and -3- and banjo bolt -4-.
rig
gh ht
pyri by
Vo
co
– Open connection to oil supply line, separate support from oil
by lksw
cted agen
Prote
supply line and remove.
AG.

Sharan 2011 ➤
– Undo oil supply line -2- at turbocharger.

– Unscrew bolts -arrows- and remove heat shield.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
210
cop Vo
by lksw
Rep. gr.21 - Turbocharging/supercharging Prote
cted AG.
agen
n AG. Volkswagen AG do Sharan 2011 ➤
wage es n
4-cylinder common y Vorail engine (2.0 l, EA189 Gen
lks otII)
gu - Edition 10.2018
db ara
ir se nte
– Unscrew nuts -arrows-. ut
ho eo
ra
a c
ss
– Remove turbocharger together with exhaust manifold from
ce
le
un
cylinder head and turn so that the intake side is facing down‐
pt
an
d
wards.
itte
y li
erm
ab
– Remove turbocharger together with exhaust manifold down‐
ility
ot p
wards.
wit
is n
h re
ole,
Installing
spec
t to the co
⇒ “1.3 Assembly overview - turbocharger”, page 205 .
rrectne
Note
ss o
cial p
f in
♦ Renew seals, gaskets, O-rings and self-locking nuts.
form
mer
♦ Fill turbocharger with engine oil at connection for oil supply
atio
m
line.
o
n
c
i
or
n thi
e
t
sd
va

i
o
pr
cum
r
fo
en
♦ Secure all hose connections with the hose clips corresponding
ng
t.
yi Co
to original equipment ⇒ Electronic Parts Catalogue . t. Cop py
rig
gh ht
♦ After installing turbocharger, run engine for about 1 minute at pyri by
Vo
co
idling speed to ensure that oil is supplied to turbocharger. Do
by lksw
cted agen
Prote
not rev engine immediately.
AG.
♦ Fit thermal sleeves in same place when installing turbocharg‐

er.

– Install exhaust gas recirculation pipes ⇒ page 304 .
– Connect vacuum hoses ⇒ page 224 .
– Install particulate filter ⇒ page 274 .
1.5 Replacing vacuum unit with position

sender for charge pressure positioner -
G581-
Note
Socket, 10 mm - T10422 A- replaces the previous socket, 10 mm

- T10422- . Existing sockets without the suffix »A« may continue
to be used.

Sharan 2011 ➤
♦ Socket, 10 mm - T10422-
♦ Ring spanner 10x12 - T10423-
. Volkswagen AG
gen AG does
swa
♦ Hand operated vacuum yV
olk pump - VAS 6213- not
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ise nte
or eo
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aut ra
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Vehicle diagnostic tester

rrectness of i
♦ Red paint, e. g. touch-up pencil “Mars Red” - L 0A3 A01-

l purpos
Caution
nform
mercia
The special tools indicated, in particular the 10 mm socket in‐

com
tion in
sert - T10422- or 10 mm socket insert - T10422 A- is designed

r
te o
solely for use according to the following work instructions. Do

thi
s
iva
not use it for other threaded connections. There is a danger of

do
r
rp
deformation if high torques are applied.

um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Note
by lksw
cted agen
Prote AG.
A spare-parts kit is available ⇒ Electronic parts catalogue (ETKA)

for replacing the vacuum unit with position sender for charge
pressure positioner - G581- .

Sharan 2011 ➤
Removing
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
– Open heat-protection mat and disconnect electrical connector
-arrow- at position sender for charge pressure positioner -
G581- .
– Remove crankcase breather connecting pipe-1- from cylinder

head cover by pressing release buttons.
olkswagen AG
en AG. V
– Unscrew bolt -2- (captive), swingoairlkswpipe with inlet connection
ag does
not
to rear and pull off from turbocharger.
ed
byV gu
ara
is nte
or
– Seal opening in turbocharger
au
th with the sealing cap from the eo
ra
spare-parts kit. ss c
ce
e
nl
pt
– Pull vacuum line off vacuum unit.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Counterhold lock nut -B- and unscrew securing nut -A- from
hole
the control rod using socket, 10 mm - T10422- or socket, spec

es, in part or in w
10 mm - T10422 A- . t to the co
Note
rrectness of i
l purpos
The securing bolts of the vacuum unit may have an M6 hexagon

head or M8 hexagon socket head. The tightening torque is the
same for either one.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Unscrew securing bolts of the vacuum unit -arrows- and re‐

p
move the vacuum unit with position sender for charge pres‐
um
for
en
g
sure positioner - G581- -A-.

n
t.
yi Co
Cop py
Installing ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Caution Prote AG.
Only use new bolts and nuts from the spare-parts kit!
– If necessary, remove lower securing nut of the control rod from

the new vacuum unit.
– Screw locknut by hand onto the control rod as far as possible
in the direction of the vacuum unit.

Sharan 2011 ➤
– Push control rod through the adjusting lever, fit vacuum unit
with position sender for charge pressure positioner - G581-
-A- and tighten fastening bolt.
– Tighten securing bolts -arrows- to 8 Nm.
Note
wage es n
Make sure that the guiding element moves easilyby along
Volks
the con‐ ot g
ua
trol rod. ir se
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
– Connect connector -arrow- to the position sender for the
y li
erm
ab
charge pressure positioner - G581- and close the heat pro‐
ility
ot p
tection mat.
wit
, is n
– Connect vehicle diagnostic tester .
h re
hole
spec
Select operating mode:
es, in part or in w
t to the co
– Click the “Vehicle self-diagnosis” button on the display.
Select vehicle system:
rrectness of i
– Press button “01 - Engine electronics” on display.
l purpos
The display shows the identification of the engine control unit.

Selecting diagnostic function:
nform
ercia
– Click the “011 - Measured values” button on the display.

m
at
om
ion
c
– In the selection list, select “Positioner for high pressure, tur‐
in t
or
bocharger, actual input voltage” and switch until measured
his
ate
value is displayed.
do
priv
cum
for
– Connect hand vacuum pump - VAS 6213- to vacuum unit. en

ng
t.
yi Co
op
– While observing the displayed measured value, set a voltage
C py
t. rig
gh
of 760 mV by creating a vacuum of max. 0.65 bar.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
During the following procedure for adjusting the control rod,

keep the partial vacuum and thus the voltage of 760 mV con‐
stant.

Sharan 2011 ➤
– Slowly screw the locknut-B- of the control rod downwards by

hand. Adjusting lever is resting on the lower »stop«.
– Counterhold locknut -B- and screw securing nut -A- onto the
control rod towards the adjusting lever. Tighten slightly with a
ring spanner 10x12 - T10423- .
– Allow partial vacuum to escape from the vacuum unit.
– Observe displayed measured value; value at normal pressure
must be set at 3000 … 3400 mV.
– Fit socket AF 10 - T10422- or socket AF 10 - T10422 A- ,
counterhold lock nut -B- and tighten securing nut -A-.
Caution
Create a partial vacuum of 0.65 ± 0.05 bar to act on the vacuum

unit in order to ensure that the adjusting lever rests against the
»stop«. When this is done, the voltage should automatically be
set to 760 mV.
Voltage OK.
– Press locking plate by hand onto the control rod and, if possi‐
ble, turn 90° in the -direction of the arrow-.
– Mark body of vacuum unit with a dot of red colour where it can
be clearly seen, using e. g. touch-up pencil “Mars Red” - L 0A3
A01- .
Voltage not OK.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
– Counterhold
s au locknut -B-, undo securing nut -A- of the ra
c control
rod and correct the voltage by turning the locknut -B-.
s
ce
le
un
pt
– Counterhold locknut -B-, turn securing nut -A- in opposing di‐

an
d
itte
y li
rection and tighten it with socket inset SW 10 - T10422- .

erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Press locking plate by hand onto the control rod and, if possi‐
ble, turn 90° in the -direction of the arrow-.
– Mark body of vacuum unit with a dot of red colour where it can
be clearly seen, using e. g. touch-up pencil “Mars Red” - L 0A3
A01- .
Continuation
– Remove sealing cap from turbocharger.
– Re-install all engine components.
– Start engine, and clear event memory ⇒ Vehicle diagnostic
tester.
– Check setting as follows: n AG. Volkswagen AG do
lkswage es n
o ot g
yV
Selecting diagnostic function: d b ua
ran
ir se tee
ho
– Click the button “006 - Basic setting” on
au the display.
t or
ac
ss
– Select “Adaptation of turbocharger” from selection list.
ce
le
un
pt
an
d
itte
– Click the button “Measured values” on the bottom right on the
y li
erm
ab
display.
ility
ot p
– Select “Positioner for high pressure, turbocharger, actual input
wit
is n
h re
voltage” from selection list.
ole,
spec
– Click the “Start” button on the bottom right on the display.
t to the co
– Observe value in lower window. It must fluctuate between
650 … 850 mV and 3000 … 3400 mV (vacuum unit is moved
to both end stops alternately).
rrectne
If voltage values are OK:
ss
– End basic setting procedure.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Sharan 2011 ➤
d
4-cylinder
rise common rail engine (2.0 l, EA189 Gen nteII) - Edition 10.2018
tho eo
s au ra
c
s
ce
2 Charge air system
le
un
pt
an
d
itte
y li
⇒ “2.1 Installing hose connections with plug-in connectors”, page
erm
ab
217
ility
ot p
wit
is n
⇒ “2.2 Installing hose connections with corrugated pipe connec‐
h re
ole,
tion”, page 218
spec
⇒ “2.3 Assembly overview - parts of charge air cooling”,
t to the co
page 218
⇒ “2.5 Checking charge air system for leaks”, page 220
rrectne
⇒ “2.6 Vacuum hose connection diagram”, page 224
s
⇒ “2.7 Checking vacuum system”, page 224
s o
cial p
f in
2.1 Installing hose connections with plug-in
form
mer
connectors
atio
om
n
c
i
or
n thi
e
Caution
t
sd
iva
o
pr
cum
r
fo
The seal for the push-on coupling can be damaged if the re‐
en
ng
t.
yi
taining clip is in the locked position during installation. This
Co
op py
would result in leaking. Observe installation instructions. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Release plug-in connector by pulling securing clip -1-. Pull
hose/pipe-2- off without the use of tools.
Installing
– If renewed, place seal in groove of charge air hose. Ensure
the seal is correctly seated in the groove.
– Lubricate sealing surface and seal with oil.
– Bring retaining clip to release position -1-.
– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if plug-in connector seats correctly and is properly en‐
gaged by pulling hose.
2. Charge air system 217

Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Editionen10.2018
AG. Volkswagen AG
ag does
ksw not
Vol gu
2.2 Installing hose connections with corru‐ by ara
ed nte
oris
gated pipe connection th eo
s au ra
c
s
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Check all air hoses and pipes for firm seating and leaks before
ot
wit
, is n
carrying out tests or repairs.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ In order to be able to securely attach the air hoses on their
connections, the worm screws of the used hose clips have to
l purpos
be sprayed with penetrating spray before installing.
nform
mercia
Caution
a
com
tion in
r
te o
The screw-type clips -A- on the charge air lines must always
thi
s
be tightened as specified ⇒ page 218 . If the torque is too low
iva
do
r
or too high, the charge air hose may slip off the corrugated pipe
rp
cum
fo
connection or the charge air pipe when the vehicle is used.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Installing air hoses with screw-type clips
lksw
cted agen
Prote AG.
Specified torques for
1- Hose clip -a- = 13 mm wide: 5.5 Nm
2- Hose clip -b- = 9 mm wide: 3 Nm
2.3 Assembly overview - parts of charge air

cooling
Note
♦ All hose connections of charge air system are secured by

spring-type clips, plug-in connectors or spring band rings.
When installing, observe installation instructions for plug-in
connector ⇒ page 217 .
♦ The charge air system must be free of leaks.
♦ Checking charge air system for leaks ⇒ page 220 .

Sharan 2011 ➤
Caution
It is essential for the screw-type clamps on the charge air lines

to be tightened to 5.5 Nm. If the tightening torque is too low or
too high, the charge air hose may slip off the charge air pipe
when the vehicle is being driven.
Assembly of hose connections ⇒ page 217 .
1 - 5 Nm
2 - Mountings
❑ For charge air cooler
3 - Charge air cooler
⇒ page 219
4 - Connection hose
❑ »Cold« side, bottom
5 - Screw-type clip, 5.5 Nm
6 - To throttle valve module -
J338-
7 - Connection hose AG. Volkswagen AG d
agen oes
❑ »Cold« side, top olksw not
byV gu
ara
ed
8 - Charge air pressure sender horis nte
eo
- G31- with intake air tempera‐ aut ra
s c
ture sender - G42- s
ce
e
nl
pt
du
9 - 2 Nm
an
itte
y li
erm
ab
10 - Rubber grommet
ility
ot p
wit
, is n
11 - 8 Nm h re
hole
spec
es, in part or in w
12 - Charge air pipe

t to the co
❑ »Cold« side
13 - Connection hose
rrectness of i
❑ »Hot« side, top

l purpos
14 - From turbocharger
15 - Charge air pipe
nform
ercia
❑ »Hot« side
m
at
om
io
n
c
in t
or
his
e
❑ »Hot« side, bottom

at
do
priv
cum
for
en
ng
t.
yi
2.4 Removing and installing charge air cool‐
Co
Cop py
ht. rig
er
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
The charge air cooler can only be removed together with the con‐
denser.

Sharan 2011 ➤
Removing
– Extract refrigerant from air conditioning system ⇒ Heating, air
conditioning system; Rep. gr. 87 .
– Removing radiator ⇒ page 151 .
– Unscrew coolant lines -arrow- from condenser.
– Remove connecting hoses leading to charge air cooler .
– Remove side air ducting at front end ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front .
– Remove middle guide profile at front end ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumpers .
AG. Volkswagen AG d
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nl
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an
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– Tip charge air cooler together with condenser towards the en‐
y li
erm
ab
gine and pull upwards out of brackets.
ility
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– Take charge air cooler together with condenser out from un‐
wit
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derneath.
h re
hole
spec
Installing
es, in part or in w
t to the co
following:
rrectness of i
Specified torques ⇒ page 218
l purpos
Fill charge air conditioning system with refrigerant ⇒ Heating, air

conditioning; Rep. gr. 87 .
nf
ercia
2.5 Checking charge air system for leaks

rm
m
atio
om
n in

or c
thi
te
♦ Charge air system tester - V.A.G 1687- with adapter - V.A.G

sd
iva
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r
1687/12-
rp
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Cop py
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Prote AG.

Sharan 2011 ➤
Procedure
– Release hose clip -3- and remove air pipe from air filter hous‐
ing.
lkswage es n
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yV
– Insert adapter - 1687/10- in intake hose -1- and secure
ir se
d b with ua
ran
clip. tho tee
or
au ac
s
– Insert adapter - 1687/12- in intake hose -1- and secure with
s
ce
le
clip.
un
pt
an
d
itte
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Prepare charge air system tester - V.A.G 1687- as follows:
rm
ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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com
tion in
– Unscrew pressure regulating valve -2- and close valves -3-
r
te o
thi
and -4-.
s
iva
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rp
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fo
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ng
t.
Note
yi Co
Cop py
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To turn the pressure regulating valve -2- the knob must be pulled p by
co Vo
upwards.
by lksw
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Prote AG.

Sharan 2011 ➤
– Connect charge air system tester - V.A.G 1687- to adapter -

1687/12- as shown.
AG. Volkswagen AG d
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un
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itte
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ab
ility
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wit
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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n thi
te
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Cop py
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by
cted agen
Prote AG.

Sharan 2011 ➤
– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
AG. Volkswagen AG d
– Open valve -3-. agen oes
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– Adjust pressure to 0.5 bar with pressure regulating
rised
valve -2-. nte
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Caution
ce
le
un
pt
an
d
itte
The pressure must remain at or below 0.5 bar! If the pressure
y li
erm
ab
is too high this can cause damage to the engine.
ility
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wit
is n
h re
ole,
– Open valve -4- and wait until the test circuit is filled. If neces‐
spec
sary readjust pressure to 0.5 bar.
t to the co
– Check charge air system for leaks by:
♦ listening
rrectne
♦ feeling
s
♦ using standard leak detecting spray
s o
cial p
f in
♦ Ultrasonic tester - V.A.G 1842-
form
mer
atio
om
n
Note
c
i
or
n thi
te
sd
va
♦ Slight leaks on the intake side of turbocharger are permissible,

i
o
pr
cum
as the intake hoses are not designed for high-pressure.
r
fo
en
ng
t.
yi
♦ A small amount of air escapes through the valves and enters
Co
Cop py
the engine. Therefore a holding pressure test is not possible.
t. rig
gh ht
pyri by
Vo
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♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions
by c lksw
cted agen
Prote AG.
♦ If a leak has been found, observe notes for charge air system
during assembly work.
♦ Depressurise test circuit by detaching coupling from adapter -
1687/10- before removing adapter.
Installing
Note
♦ Renew seal and O-rings.

– Installing inlet connection and pulsation damper ⇒ page 205 .


Sharan 2011 ➤
2.6 Vacuum hose connection diagram
Caution
Do not kink, twist or crush theagvacuum

en AG. V lines when
olkswagen AG d routing vac‐
uum lines. This may cause breakdowns.
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1 - Pressure canister
ce
le
un
pt
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❑ On turbocharger.
itte
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erm
ab
❑ With position sender for
ility
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charge pressure posi‐
wit
is n
tioner - G581-
h re
ole,
2 - Charge pressure control
spec
solenoid valve - N75-
t to the co
3 - Silencer
4 - Air filter
rrectne
5 - To brake servo
ss
6 - Connection piece
o
cial p
f in
❑ On vacuum pump
form
mer
7 - Non-return valve atio

om

c
i
or
sition
thi
te
sd
iva
o
r

p
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fo
cooler changeover valve -

en
ng
t.
N345-
yi Co
Cop py
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9 - Cylinder head cover
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10 - Vacuum unit cted agen
Prote AG.
❑ For changeover for ex‐
haust gas recirculation
cooler.
2.7 Checking vacuum system
Caution
Do not kink, twist or crush the vacuum lines when routing vac‐
uum lines. This may cause breakdowns.

Sharan 2011 ➤
♦ Hand operated vacuum pump - VAS 6213-
⇒ “2.7.1 Checking supply line, vacuum reservoir and non-return

valve”, page 225
⇒ “2.7.2 Checking control line to turbocharger”, page 226
⇒ “2.7.3 Checking control line to vacuum unit for exhaust gas re‐
circulation cooler changeover function”, page 227
2.7.1 Checkingkssupply
wage
n AG. Vline, vacuum
olkswagen AG
does reservoir
not
l
and enon-return valve
o
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d
is n tee
or
– Remove engine
au
th cover panel ⇒ page 7 . or
ac
ss
– Unclip exhaust gas recirculation cooler changeover valve -
ce
e
nl
pt
N345- from retainer located on front of intake manifold.

du
an
itte
y li
erm
– Pull vacuum hose at lower connection -arrow in I- off exhaust

ab
ility
gas recirculation cooler changeover valve - N345- and off

ot p
wit
charge pressure control solenoid valve - N75- -arrow in II-.

, is n
h re
hole
– Seal open hose ends with suitable blanking plugs.

spec
es, in part or in w
t to the co
Note
rrectness of i
Do not use screws or threaded bolts.

l purpos
– Pull vacuum hose -arrow- off connection piece of vacuum

pump.
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orm
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om
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te
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rp
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Cop py
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by
cted agen
Prote AG.

Sharan 2011 ➤
– Connect hand vacuum pump - VAS 6213- to disconnected

hose and generate a vacuum of 0.6 bar.
– Observe hand vacuum pump pressure gauge for approx. 30
seconds.
• Vacuum must not drop.
If vacuum drops:
– Locate damage or leak in hose and renew that section of hose.
If pressure does not drop:
– First pull hose off hand vacuum pump - VAS 6213- .
– Remove one of the blanking plugs from hose ends. n AG. Volkswagen AG do
lkswage es n
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– If the non-return valve functions properly, a clear hiss is audi‐ ed by V ua
ran
ble when vacuum in vacuum reservoir is released. ho
ir s tee
ut or
a ac
If no hiss is audible: ss
ce
le
– Renew non-return valve. un
pt
an
d
itte
y li
If a hiss is audible:
rm
ab
pe
ility
– Reconnect all disconnected vacuum hoses.
ot
wit
, is n
h re
– Check control line to turbocharger ⇒ page 226 .
hole
spec
es, in part or in w
t to the co
2.7.2 Checking control line to turbocharger
– Pull hose off middle connection of charge pressure control
rrectness of i
solenoid valve - N75- -arrow in I- and off turbocharger vacuum
unit -arrow in II-.
l purpos
– Seal one hose opening using a suitable blanking plug.
nform
ercia
Note
m
a
com
tion in
r
Do not use screws or threaded bolts.

te o
thi
s
iva
do
r
rp
c
– Connect hand vacuum pump - VAS 6213- to other hose end
um
fo
en
g
and generate a vacuum of 0.6 bar.

n
t.
yi Co
op py
– Observe hand vacuum pump pressure gauge for approx. 30
t. C rig
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seconds. p by
co Vo
by lksw
cted agen
• Vacuum must not drop. Prote AG.
If vacuum drops:
– Renew vacuum hose.
If pressure does not drop:
– Reconnect all disconnected vacuum hoses.
– Checking control line to vacuum unit for exhaust gas recircu‐
lation cooler changeover function ⇒ page 227 .

Sharan 2011 ➤
2.7.3 Checking control line to vacuum unit for

exhaust gas recirculation cooler
changeover function
– Pull hose off upper connection of exhaust gas recirculation
cooler changeover valve - N345- -arrow-.
– Connect hand vacuum pump - VAS 6213- to disconnected
hose and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump for approx.
30 seconds. Vacuum must not drop.
If the pressure drops:
– Pull vacuum hose off vacuum unit for exhaust gas recirculation AG. Volkswagen AG d
cooler changeover function. agen oes
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– Connect hand vacuum pump - VAS 6213- to vacuum ris
e unit with nte
ho bar.
test hose supplied and generate a vacuum ofaut0.6 eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
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erm
ab
ility
♦ The vacuum unit control range must be perceptible and the
ot p
vacuum must not drop. If this is not the case, renew the ex‐
wit
is n
h re
haust gas recirculation cooler ⇒ page 272 .
ole,
spec
♦ If no fault can be detected on the vacuum unit, renew the vac‐
t to the co
uum line from the exhaust gas recirculation cooler changeover
valve - N345- .
rrectne
– Install engine cover panel ⇒ page 7 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
AG. Volkswagen AG d
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23 – Mixture preparation - injection
ol not
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1 Diesel direct injection system
s
ce
e
nl
pt
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itte
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erm
ab
Note
ility
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wit
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The diesel direct injection system control unit is equipped with an
h re
hole
event memory. Read event memory before and after making re‐
spec
pairs or adjustments.
es, in part or in w
t to the co
⇒ “1.1 Safety precautions”, page 228
rrectness of i
⇒ “1.2 Rules for cleanliness”, page 228
l purpos
⇒ “1.3 System layout”, page 229
nform
mercia
at
om
WARNING
ion
c
in t
or
his
e

at
do
riv

p
cum
for
en
g

n
t.
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restored. Cop py
ht. rig
rig ht
♦ Ensure that there is sufficient clearance to all moving or py by
co Vo
hot components.
by lksw
cted agen
Prote AG.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test equipment must always be secured on the rear seat and
operated by a 2nd person.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐
connecting preglow and injection system wiring as well as test
equipment leads.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.
1.2 Rules for cleanliness

When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
♦ Before disconnecting, thoroughly clean all unions and adja‐
cent areas e.g. with brake cleaner.
♦ Carefully cover opened components and connections or seal
if repairs cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
228 Rep. gr.23 - Mixture preparation - injection

Sharan 2011 ➤

toolboxes).
move the vehicle.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 System layout
WARNING
♦ Always read rules for cleanliness and instructions for

working on fuel system ⇒ page 228 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ If components of the fuel system between the tank and the
high-pressure fuel pump are removed or renewed, the fuel
system must be filled to be bled ⇒ page 235 . (It is im‐
portant not to allow the high-pressure pump to run while
still empty.)
AG. Volkswagen AG d
agen oes
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1 - Fuel aut
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❑ With fuel system pres‐ s
ce
e
nl
surisation pump - G6-

pt
du
an
itte
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2 - Fuel filter
erm
ab
ility
❑ With pre-heating valve

ot p
wit
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❑ Assembly overview -
h re
fuel filter ⇒ page 194 .

hole
spec

es, in part or in w
t to the co
⇒ page 195
3 - Not fitted
rrectness of i
4 - Filter strainer
l purpos
5 - Fuel temperature sender -

G81-
nform
ercia
m
at
❑ After renewing, a first

om
io
fuel filling must be per‐

n
c
in t
r
formed (never allow the

o
his
te
pump to run while it is

a
do
riv
still empty)
p
cum
or
⇒ page 235 .
f
en
ng
t.
yi Co
❑ Removing and installing Cop py
t. rig
⇒ page 232 opyri
gh by
Vo
ht
by c
7 - Fuel metering valve - N290-
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cted agen
Prote AG.
❑ Must not be removed.
8 - Fuel pressure regulating
valve - N276-
❑ Installing and removing
⇒ page 249
1. Diesel direct injection system 229

Sharan 2011 ➤
9 - High-pressure accumulator (rail)

10 - Fuel pressure sender - G247-
❑ Installing and removing ⇒ page 250
11 - Non-return valve
❑ The non-return valve must be renewed only as a unit together with the fuel return lines.
❑ After renewal, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
12 - Injectors
❑ Injector, cylinder 1 - N30-
❑ Injector, cylinder 2 - N31-
❑ Injector, cylinder 3 - N32- n AG. Volkswagen AG do
wage es n
❑ Injector, cylinder 4 - N33- yV
olks ot g
ua
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❑ Installing and removing ⇒ page 242orise ran
te
th eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
2 High-pressure pump
⇒ “2.1 Assembly overview - high-pressure pump”, page 231
⇒ “2.2 Removing and installing high-pressure pump”, page 232
⇒ “2.3 Filling/bleeding fuel system”, page 235
⇒ “2.4 Checking for leaks in the fuel system”, page 236
2.1 Assembly overview - high-pressure pump
⇒ page 35
AG. Volkswagen AG d
2 - 20 Nm + turn 180° further ksw
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❑ Renew ed by gu
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3 - Hub aut
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❑ Use counter-hold tool - s
ce
le
T10051- to loosen and

un
pt
an
d
tighten
itte
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erm
ab
❑ To remove, use puller -
ility
ot p
T40064- .
wit
is n
h re
4 - High-pressure pump tooth‐
ole,
spec
ed belt pulley
t to the co
5 - 20 Nm
6 - 95 Nm
rrectne
❑ Renew
ss o
cial p
f inform
❑ With fuel metering valve

mer
- N290- (do not open)

atio
om
❑ After renewing, initial

n
c
i
or
fuel filling must be car‐

thi
te
sd
ried out (never allow

iva
o
r
pump to run dry)

p
cum
r
fo
⇒ page 235 .
en
ng
t.
yi Co
❑ Removing and installing Cop py
t. rig
⇒ page 232 opyri
gh by
Vo
ht
by c lksw
9 - Fuel supply hose Prote
cted AG.
agen
10 - Fuel return hose

11 - High-pressure lines,
28 Nm
❑ Between high-pressure pump and fuel rail.
❑ Do not interchange
Note
♦ Observe cylinder-specific mark‐

ings if reusing high-pressure
lines.
♦ The high-pressure lines may be
re-used after the following
checks:
2. High-pressure pump 231

Sharan 2011 ➤
♦ Check taper seat of respective

high-pressure line for deforma‐
tion and cracks.
♦ The inside of the line must be
free of deformations, constric‐
tions and damage.
♦ Corroded lines should no longer
be used.
❑ Install so that component is not under tension
2.2 Removing and installing high-pressure pump
Special tools and workshop n AG. Volkswagen AG do

equipment required lkswage es n
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pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Puller - T40064- with T40064/1

Sharan 2011 ➤
Removing
Caution
G. Volkswage
♦ Always observe ruleslksfor
wagcleanliness
en A andn Ainstructions
G do
es n
when working on
db
fuel
y V system ⇒ page 228 .
o ot g
ua
ran
ise
♦ Always follow ho these rules for cleanliness and instructionse o
r e t
ut
before starting work and while working on the fuel system. ac
a r
ss
ce
e
Risk of irreparable damage to high-pressure pump if allowed

nl
pt
du
an
to run dry.
itte
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erm
ab
♦ The high-pressure pump must first be filled with fuel before
ility
ot p
the engine is started. Do not run the high-pressure pump
wit
, is n
while empty. Initial fuel filling ⇒ page 235 .
h re
hole
spec
es, in part or in w
t to the co
– Remove toothed belt from camshaft and high-pressure pump
⇒ page 77 .
– Unscrew bolts -2-, remove toothed belt sprocket from high-
rrectness of i
pressure pump.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Unscrew nut -1- on hub of high-pressure pump; counterhold
op Vo
by c lksw
with counter-hold tool - T10051- for this.
cted agen
Prote AG.
– Apply puller - T40064- with thrust piece - T40064/1- and pin -

T40064/2- as shown in illustration and pull hub off high-pres‐
sure pump. If necessary, counterhold with a 24 mm open-end
spanner.

Sharan 2011 ➤
– Unscrew bolts -2-, lay coolant return line aside.
– Unscrew bolts -arrows-, lay coolant return line aside.
– Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure
line.
AG. Volkswagen AG d
agen oes
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nl
pt
du
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itte
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erm
ab
ility
ot p
– Separate electrical connectors -1- and -3-.

wit
, is n
h re
– Remove fuel supply hose -2- and return hose -4-.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Unscrew bolts -arrows- for high-pressure pump.

– Carefully remove high-pressure pump.
Installing
⇒ “2.1 Assembly overview - high-pressure pump”, page 231
– Install toothed belt ⇒ page 77 .
– Install high-pressure lines ⇒ page 246 .
Caution

to run dry.
while empty. Initial fuel filling ⇒ page 235 .
AG. Volkswagen AG d
agen oes
lksw not
2.3 Filling/bleeding fuel system Vo gu
d by ara
ise nte
or eo
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aut ra
Caution ss c
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le
un
pt
an
d

itte
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to run dry.
erm
ab
ility
ot p
wit
is n
h re
ole,
while empty.
spec
t to the co
Note rrectne
♦ When installing the high-pressure pump, it is essential to en‐

ss
sure that no dirt enters the fuel system.

o
cial p
f in
♦ Only remove sealing plugs immediately prior to installation of

form
mer
fuel lines.
atio
m
♦ Vehicle must have fuel.

o
n
c
i
or
n thi
te
sd
a
Proceed as follows to fill high-pressure pump with fuel:

iv
o
pr
cum
r
fo
– Switch on ignition.
en
ng
t.
yi Co
op
– Connect vehicle diagnostic tester and perform the guided
C py
t. rig
gh
function “Bleeding fuel system” or “Filling/bleeding fuel sys‐
ht
pyri by
Vo
o
tem” depending on software version. by c lksw
cted agen
Prote AG.
Note
The fuel pumps will now be actuated for a total of three minutes.
– Then start engine.

– After filling fuel system, leave engine running at moderate
speed for a few minutes and then switch off again.
– Check fuel system for leaks.

Sharan 2011 ➤
– Read event memory and erase stored event entry if necessa‐

ry.
– Then perform an extensive test drive with at least one full ac‐
celeration. Then check high-pressure part of fuel system again
for leakage.
Note
If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Switch engine off and
clear event memory. Then continue road test.
– Read event memory again.
Note
emergency running mode during road test. Switch off the engine
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and erase the fault memory. Then kcontinue
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– Read event memory. horis nte
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2.4 Checking for leaks in the fuel system
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– Check the entire fuel system for leaks.

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Renew the affected component if leakage still occurs after tight‐

ening to the correct torque.

t to the co
– After completing the repair, road-test the vehicle. Accelerate

with full throttle at least once. Then check the high-pressure
rrectne
section of the fuel system again for leaks.

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Note
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Sharan 2011 ➤
3 Injectors
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When installing
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⇒ “3.1 Assembly overview - injectors”, page 237
es, in part or in w
t to the co
⇒ “3.2 Carrying out adaptation for injector delivery calibration”,
page 240
rrectness of i
⇒ “3.3 Checking for injectors sticking open”, page 241
⇒ “3.4 Removing and installing injectors”, page 242
l purpos
⇒ “3.5 Installing high-pressure lines”, page 246
nf
ercia
o
⇒ “3.6 Checking fuel pressure regulating valve N276 ”,
rm
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page 247
atio
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⇒ “3.7 Removing and installing fuel pressure regulating valve

or
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N276 ”, page 249

t
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⇒ “3.8 Removing and installing fuel pressure sender G247 ”, page

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250
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⇒ “3.9 Removing and installing fuel rail”, page 252
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3.1 Assembly overview - injectors
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3. Injectors 237
Sharan 2011 ➤
1 - Seal
❑ In cylinder head cover
⇒ page 76
2 - Copper washer
❑ Renew
3 - O-ring
❑ Renew
4 - Injector
❑ When removing and in‐
stalling, always renew
the following compo‐
nents and seals/O-
rings: “copper seal”, “O-
ring for injector bore”,
“O-ring for injector re‐
turn connection”.
❑ The following compo‐
nents and seals or O-
rings must always be
renewed when an injec‐
tor is renewed: “copper
seal”, “O-ring for injector
bore” and “O-ring for in‐
jector return connec‐
tion”
❑ Before re-using “high-
pressure injector line”,
perform visual check of
taper seats for damage
such as transverse
scores or corrosion; al‐
ways renew if damaged.
❑ Before installing, clean n AG. Volkswagen AG do
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cleaning set - VAS d b ua
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❑ If they are to be reinstalled, the injectors,
ss high-pressure lines and clamping pieces must only ever be
refitted on the same cylinder.
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5 - O-ring
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❑ Renew
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❑ To fuel tank
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❑ Check for correct engagement

❑ Must not be kinked, damaged or blocked.
rrectness of i
❑ Do not dismantle.
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❑ After renewal, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then check
fuel return lines for leaks.
nform
ercia

m
❑ Renew
a
com
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8 - Clamping piece
r
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❑ If they are to be reinstalled, the injectors and clamping pieces must only ever be refitted on the same
s
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cylinder.
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❑ Fitting position ⇒ page 240

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238
Prote AG.
Rep. gr.23 - Mixture preparation - injection
AG. Volkswagen AG d
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9 - High-pressure line, 28 Nm
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❑ Between fuel rail and injectors.
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spec
t to the co
lines.
rrectne
checks:
ss
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tion and cracks.
mer
atio
♦ The inside of the line must be om
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tions and damage.
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be used.
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❑ Install so that component is not under tension
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10 - 22 Nm
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11 - High-pressure accumulator (rail)
12 - Fuel return hose
13 - Fuel pressure regulating valve - N276- , 80 Nm.
❑ Renew after each removal
14 - O-ring
❑ Renew
15 - High-pressure line, 28 Nm
❑ Between high-pressure pump and fuel rail.
Note

lines.
checks:
tion and cracks.
♦ The inside of the line must be
tions and damage.
be used.
16 - 8 Nm
❑
17 - Fuel pressure sender - G247- , 100 Nm
3. Injectors 239
Sharan 2011 ➤
18 - Grommet
❑ In cylinder head cover
Clamping piece installation position

• One clamping piece encompasses 2 injectors each.
• Thick part -arrow- of clamping piece points downwards.
3.2 Carrying out adaptation for injector de‐

livery calibration
The “injector delivery calibration (IMA)” function serves to correct
the injection rates for each cylinder of a common rail system in‐
dividually across the entire ignition map range.
The 7-digit adaptation values -1- (details in illustration are only an
example) are marked separately on each injector. The marked
values may consist of letters and/or numbers.
Top view of injector
1 - Checksum
2 - Data Matrix Code
3 - Part number
After renewing an injector, the adaptation
wage
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After renewing the engineris control unit, the “adaptation values forntee
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the injectors” mustsbe
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s
The adaption procedure is described in the Guided Fault-Finding.
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(The procedure is also described under Guided Functions).

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Additionally check that the “injector delivery calibration values”

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are correctly entered for all the other injectors. Do not attempt to
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re-enter these values if the correct values are already stored in

h re
the engine control unit.

ole,
spec
Select the correct vehicle in Guided Fault Finding.

t to the co
– Press “GoTo” button.

– Press “Function/component selection”.
rrectne
– Select “Drive train”.

ss
– “01 - Self-diagnosis compatible systems”

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– “01 - Engine electronics J623”

form
mer
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– Select “01 - Functions of engine electronics”

om
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or
– Select “01 - Adapt injector delivery calibration”

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Sharan 2011 ➤
3.3 Checking for injectors sticking open
WARNING

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♦ Hand operated vacuum pump - VASs 6213-
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ility
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es, in part or in w
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rrectness of i
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♦ Make an -adapter- from a return line.
nform
mercia
at
om
ion
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in t
or
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ate
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– Clear fault memory entry using vehicle diagnostic tester.

– Clean all connections (e.g. with commercial cleaning solution)
before removing.
Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check all cylinders in turn.
– Dry all components after cleaning.

Start with cylinder 1.
3. Injectors 241
Sharan 2011 ➤
– Pull return line connection off at injector. To do this, press clips

-1- and -2- down and simultaneously pull release pin upwards
-arrow-.
– Connect clean, blown-out adapter to injector to be tested.
– Use hand vacuum pump - VAS 6213- to generate vacuum of

approx. -500 mbar.
If injector is OK, pressure remains constant for 30 seconds.
If injector is defective, pressure drops to 0 bar within 2 or 3 s.
Repeat check is necessary, observe pressure loss at hand-oper‐
ated vacuum pump - VAS 6213- .
– Renew defective injectors ⇒ page 242 .
AG. Volkswagen AG d
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3.4 Removing and installing injectors ise nte
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Special tools and workshop equipment required s
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♦ Puller - T10055-
an
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♦ Assembly sleeve - T10377-

mer
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♦ Puller -T10415-

Sharan 2011 ➤
Removing
WARNING


Caution
♦ Mark cylinder numbers on injectors. Injectors must always

be re-installed on the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ Plug open connections with suitable sealing caps imme‐
diately.
– Pull return line connections off at injectors. To do this, press

bows -1- and -2- down and simultaneously pull release pin
upwards -arrow-.
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– Detach electrical connectors -arrows- from injectors.

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Caution
wit
is n
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ole,
When releasing high-pressure line, counterhold high-pressure

spec
connection using an open-ended spanner. Leaks occur if high-

t to the co
pressure connection is released.

rrectne
– Unscrew union nuts of relevant high-pressure line -1 to 4- and

remove corresponding high-pressure line.
ss
– Unscrew securing bolt of clamping piece -1- of injector to be

o
cial p
f i
removed.
nform
mer
atio
om
n
c
i
or
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te
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3. Injectors 243
olkswagen AG
en AG. V
Sharan 2011 ➤ ksw
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– Fit puller - T10055- with puller
ss
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c
upwards using tapping movements.
ce
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pt
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Note
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Pull injector out using rotary movements in order not to damage
h re
sealing lip.
hole
spec
es, in part or in w
t to the co
– After removal, lay injectors on a clean cloth.
Important instructions for installing injectors
rrectness of i
• Clean empty injector bores and sealing surfaces in cylinder
head using cleaning set - VAS 6811- before fitting injectors ⇒
l purpos
Instructions
• When removing and installing, always renew the following
nform
ercia
components and seals/O-rings: “copper seal”, “O-ring for in‐

m
at
jector bore”, “O-ring for injector return connection”.
om
ion
c
in t
• The following components and seals or O-rings must always
or
his
e
be renewed when an injector is renewed: “copper seal”, “O-

at
do
riv
ring for injector bore” and “O-ring for injector return connec‐
p
cum
or
tion”
f
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ng
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• Lubricate all O-rings with engine oil or assembly oil before in‐ Cop py
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Prote AG.
Note
♦ Observe cylinder-specific markings if reusing high-pressure

lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ Check taper seat of respective high-pressure line for defor‐
mation and cracks.
♦ The inside of the line must be free of deformations, constric‐
tions and damage.
♦ Corroded lines should no longer be used.
If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
Caution
To remove carbon deposits from the injector sealing surface,

clean the injector seat in the cylinder head with a cloth soaked
in engine oil or rust solvent. Take care not to damage the seal‐
ing surface.

Sharan 2011 ➤
– Renew O-ring for injector bore using assembly sleeve -

T10377- .
– To avoid damaging O-ring, carefully slide new, oiled O-ring
onto fuel return connection.
– Install injectors.
– Tighten union nuts on high-pressure lines hand-tight. Ensure
that connections are not under tension.
– Press return line connections carefully over seals and onto in‐
jectors (check seal for damage before connecting return line).
The catch should engage audibly. Then press release pin
down carefully.
After renewing one or more injectors: agen
AG. Volkswagen AG d
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♦ Write adapted correction values for new injectors
ed by into engine ara
nte
control unit ⇒ page 240 . horis
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aut ra
♦ Reset learnt values of fuel pressure
s regulating valve - N276- .
s c
ce
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un
pt
♦ 01 - Engine electronics
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♦ 01 - Engine electronics functions
pe
ility
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♦ 01 - Reset adaptation values of engine ctrl. mod-
, is n
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spec
♦ Selection: Reset learnt values of dosing unit and
es, in part or in w
t to the co
pressure regulating valve
rrectness of i
l purpos
Note
nform
ercia
The high-pressure connections must not be opened for bleeding.

m
a
com
ti
– Run engine at idling speed for several minutes and then switch on in
off.
r
te o
thi
s
iva
– Switch off ignition.

do
r
rp
cum
fo
– Check the complete fuel system including the 4 return line

en
ng
t.
yi
connections for leaks ⇒ page 236 .
Co
Cop py
ht. rig
Renew the affected component if leakage still occurs after tight‐ rig ht
py by
ening to the correct torque.
co Vo
by lksw
cted agen
Prote AG.
Note
The return lines can be renewed only together with the non-return
valve as one unit.
– After completing the repair, road-test the vehicle over a dis‐

tance of at least 20 km. Accelerate with full throttle at least
once. Then inspect the high-pressure section of the fuel sys‐
tem again for leaks.
3. Injectors 245
Sharan 2011 ➤
Note
3.5 Installing high-pressure lines

♦ Socket - T40055-
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Caution s
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Release rail and clamping pieces to more easily fit injection

itte
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erm
lines free of tension. If necessary, shift rail slightly and turn

ab
ility
relevant injector slightly if required. The lines must never be

ot p
wit
bent or tensioned. Tension would otherwise cause the respec‐

is n
h re
tive line to break in the long-term.

ole,
spec
t to the co
Note
rrectne
This section describes how to install new injection lines. If you

wish to re-use existing injection lines, you must check the points
ss
listed under ⇒ Item 9 (page 239) . Apart from that the procedure
o
cial p
f i
is identical.
nform
mer
atio
m
– If it has not been done yet, loosen securing bolts of fuel rail
o
n
c
and ensure that fuel rail can be moved.

i
or
n thi
te
sd
a
– If it has not been done yet, loosen securing bolts of clamping

iv
o
r
pieces and ensure that injectors can be rotated.

p
cum
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Cop py
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246
copy Vo
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Rep. gr.23 - Mixture preparation - injection cted agen
Prote AG.
Sharan 2011 ➤
– Remove the new high-pressure line from the packaging. Re‐

move the sealing plugs and install the line between the high-
pressure pump and the fuel rail without placing it down again.
– Initially hand-tighten high-pressure line union nuts “fully” on
high-pressure pump without tools.
– Ensure that line is inserted correctly into seat. AG. Volkswagen AG d
agen oes
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– Remove the new injection lines from the packaging. Remove by Vol not
gu
ara
the sealing plugs and install the line just by itself. rise
d
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– Initially hand-tighten injection line union nuts “fully”
ss a without
u ra
c
tools.
ce
e
nl
pt
du
an
– If necessary, proceed in the same way with other injection
itte
y li
lines.
erm
ab
ility
ot p
– Use socket - T40055- to tighten all components in the specified
wit
sequence ⇒ page 247 . , is n
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hole
spec
es, in part or in w
WARNING
t to the co
The securing clamp for the high-pressure line between the
high-pressure pump and fuel rail (fuel rail) must always be in‐
rrectness of i
stalled in the correct position. Otherwise fatigue failures or
stress ruptures may occur in the high-pressure line.
l purpos
nf
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orm
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atio
om
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Installation position for the high-pressure line securing clamp

or
thi
te
sd
a
– Tighten securing clamp to 8 Nm.

iv
o
r
rp
cu
o
m
– Press return line connections carefully onto injectors (check
f
en
ng
t.
seal for damage). You should hear them click into place. Then
yi Co
op
press the release pin downwards carefully.
C py
t. rig
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yri by
– Filling fuel system ⇒ page 235 . cop Vo
by lksw
cted agen
Prote AG.
Observe tightening sequence and specified torques

Tightening sequence Specified torque
1. Securing bolt for clamping piece 8 Nm + turn 270° further
2. High-pressure line between fuel rail and injector 28 Nm
3. High-pressure fuel line between high-pressure 28 Nm
pump and fuel rail.
4. Securing bolts of fuel rail 22 Nm
5) Securing clamp for high-pressure line between fuel 8 Nm
rail and high-pressure pump
3.6 Checking fuel pressure regulating valve

- N276-
3. Injectors 247
Sharan 2011 ➤
♦ Engine plug set - VAS 6122-
♦ Measuring container, fuel-resistant
WARNING
♦ Always read rules for cleanliness when carrying out any

work on fuel system ⇒ page 228 .

– Remove fuel return hose from fuel rail; release
AG. Volkshose
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– Seal open fuel return hose risusing a bung from engine bung set
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- VAS 6122- . utho eo
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spec
t to the co
– Connect auxiliary hose -2- to return connection of fuel rail

-3-.
rrectne
– Hold auxiliary hose in measuring container -4- to measure re‐

turn quantity.
ss o
– Start engine and run at idling speed for 30 seconds.

cial p
f inform
• Specified amount in 30 seconds: 90 to 110 ml

mer
atio
m
If the specification is not attained, the fuel pressure regulating

o
n
c
valve - N276- is defective.

or
n thi
te
sd
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Prote AG.

Sharan 2011 ➤
3.7 Removing and installing fuel pressure

regulating valve - N276-
Fuel pressure regulating valve - N276- -2- is located in fuel rail. It
maintains constant pressure in fuel rail and injection lines (high-
pressure fuel circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Note
Fuel pressure regulating valve - N276- must be renewed each

time after removing.

AG. Volkswagen AG d
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Removing
pt
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WARNING
ility
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♦ Always observe rules for cleanliness and instructions
hole
spec
when working on fuel system ⇒ page 228 .
es, in part or in w
t to the co
before starting work and while working on the fuel system. rrectness of i
– Remove fuel rail ⇒ page 252 .

l purpos
– Before removal, clean area around thread for fuel pressure

regulating valve - N276- using, e.g., commercial cold cleaning
nform
ercia
solution. (No dirt must enter the bore in the fuel rail.)
m
at
om
ion
c
in t
r
Note
o
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ate
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Do not allow any cleaning agent to get into the connector, clean
p
cum
or
it carefully.
f
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ng
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Cop py
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– Dry off fuel pressure regulating valve - N276- . gh ht
pyri by
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– Loosen union nut, counterholding on hexagonal flats on hous‐ Prote
cted AG.
agen
ing. Then unscrew and remove by hand.
3. Injectors 249
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Sharan 2011 ➤ auth or
ac
ss
ce
le
un
pt
an
d
– Remove dirt from hole of fuel rail (threads and sealing sur‐
itte
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face). Do not use tools or other instruments for this purpose.
erm
ab
ility
ot p
– Seal open hole of fuel rail using a bung from engine bung set
wit
is n
- VAS 6122- .
h re
ole,
spec
Installing
t to the co
rrectne
Note
ss o
cial p
♦ The fuel pressure regulating valve - N276- has a deformable
f in
sealing lip and no separate seal; it can therefore be used only
form
mer
once.
atio
om
♦ Check that sealing surfaces (deformable sealing lip) and
n
c
i
or
n
threads on new fuel pressure regulating valve - N276- are not
thi
te
sd
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damaged.
iv
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r
fo
♦ Check sealing surface at hole of fuel rail.
en
ng
t.
yi Co
op
♦ Start of thread and deformable sealing lip of fuel pressure reg‐ C py
t. rig
ulating valve - N276- must be moistened with diesel. gh ht
pyri by
Vo
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by
cted agen
– Screw on union nut by hand.
Prote AG.
– Align new regulating valve so that the connecting line is free

of tension after connector is attached.
– Hold regulating valve in this position with an open-end spanner
on housing hexagon or use for example multi slip-joint pliers
for this.
– To tighten union nut, use a suitable torque wrench along with
a 30 mm open-end bit insert.
– Install fuel rail ⇒ page 252 .
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Check fuel system for leaks.
– Read event memory.
– Read event memory again.
3.8 Removing and installing fuel pressure

sender - G247-
Fuel pressure sender - G247- -item B- is located in fuel rail. It
measures the current fuel pressure in the high-pressure system
and transmits a voltage signal to the engine control unit - J623- .

AG. Volkswagen AG d
agen oes
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by
Vol not
gu Sharan 2011 ➤
d ara
4-cylinder
orise common rail engine (2.0 l, EA189 Gen
nte II) - Edition 10.2018
h eo
aut ra
c
♦ Engine plug set - VAS 6122- ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
mercia
WARNING
at
om
ion
c
in t
or
his
ate
do
priv
cum
or

f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
– Before removal, clean area around thread for fuel pressure
sender, using e.g. a commercially available cold cleaning sol‐
vent. No dirt must enter the bore.
Note
Do not allow any cleaning agent to get into the connector, clean
it carefully.
– Dry fuel pressure sender - G247- .

– Pull electrical connector -item B- from fuel pressure sender -
G247- .
3. Injectors 251
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Sharan 2011 ➤ rised
nte
o eo
4-cylinder common rail engine (2.0
aut l, EA189 Gen II) - Edition 10.2018
h
ra
ss c
ce
le
– Unscrew fuel pressure sender - G247- .
un
pt
an
d
itte
y li
– Remove dirt from hole of fuel rail (threads and sealing sur‐
erm
ab
face). Do not use tools or other instruments for this purpose.
ility
ot p
wit
is n
– Seal open hole of fuel rail using a bung from engine bung set
h re
- VAS 6122- .
ole,
spec
Installing
t to the co
rrectne
Note
ss o
cial p
f i
♦ Fuel pressure sender - G247- has a deformable sealing lip,
nform
not a seal, for sealing purposes.
mer
atio
m
♦ Check that sealing surfaces (deformable sealing lip) and

o
n
c
i
threads on fuel pressure sender - G247- are not damaged.
or
n thi
e
Reusing fuel pressure sender - G247- if possible if it has been

t
sd
va
tested OK.
i
o
pr
cum
r
fo
en
ng
♦ Also check sealing surface at hole of fuel rail.

t.
yi Co
op py
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
. C rig
ht ht
rig
ulating valve - N276- must be moistened with diesel. py by
co Vo
by lksw
cted agen
Prote AG.
– Screw fuel pressure sender - G247- on hand-tight.
– Then tighten fuel pressure sender - G247- to specified torque.
– After installing fuel pressure sender - G247- , leave engine
running at moderate speed for a few minutes and then switch
off again to bleed fuel system.
Note
The high-pressure connections must “not” be opened for bleed‐

ing; fuel system bleeds itself automatically.
– Read fault memory, erase if necessary.

– Carefully check the entire fuel system for leaks.
– Renew the affected component if leakage still occurs after
tightening to the correct torque.
Note
– Read fault memory again after road test.
3.9 Removing and installing fuel rail


Sharan 2011 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Removing au ac
ss
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nl
pt
du
WARNING
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Detach electrical connector -arrow- from fuel pressure regu‐
l purpos
lating valve - N276- .
nf
ercia
orm
m
atio
om
n in
or c
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te
sd
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Cop py
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pyri by
Vo
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by
cted
– Disconnect electrical connector -B- on fuel pressure sender -
agen
Prote AG.
G247- .
– Pull vacuum hose -A- from cylinder head cover.
3. Injectors 253
Sharan 2011 ➤
– Remove fuel return hose from fuel rail; release hose clip
-arrow- to do so.
– Open retaining clips -arrows- on wiring harness and pull elec‐

trical connectors off glow plugs.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
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ce
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un
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itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
– Unscrew bolt -2- and union nuts -1 and 3-, and remove high-
t to the co
pressure line.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 2011 ➤

– Remove line guide from fuel rail and place to one side.
G. Volkswagen AG d
– Remove union nuts of 4 high-pressure lines
lksw
ag-1-.
en A oes
not
o
yV gu
– After removal, lay high-pressurerilines
sed b on a clean cloth. ara
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove fuel rail; unscrew the two bolts -arrows- to do so.
rrectness of i
Installing
l purpos

nform
ercia

m
at
om
– Install high-pressure lines stress-free ⇒ page 246 . ion

c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
♦ Observe cylinder-specific markings if reusing high-pressure

t.
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op
lines.
C py
ht. rig
rig ht
py by
♦ The high-pressure lines may be re-used after the following co Vo
by lksw
checks:
cted agen
Prote AG.
♦ Check taper seat of respective high-pressure line for defor‐

mation and cracks.
♦ The inside of the line must be free of deformations, constric‐
tions and damage.
♦ Corroded lines should no longer be used.
3. Injectors 255
Sharan 2011 ➤
4 Intake manifold
⇒ “4.1 Assembly overview - intake manifold with attachments”,
page 256
⇒ “4.2 Removing and installing throttle valve module J338 ”, page
257
⇒ “4.3 Removing and installing intake manifold”, page 258
AG. Volkswagen AG d
agen oes
lksw not
4.1 Assembly overview - intake manifold with attachments Vo gu
by ara
d
rise nte
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au ra
s c
1 - Guide tube s
ce
le
un
pt
❑ For oil dipstick.
an
d
itte
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erm
2 - Seal
ab
ility
ot p
❑ Renew
wit
is n
h re
3 - Seal
ole,
spec
❑ Renew
t to the co
4 - 8 Nm
rrectne
6 - 9 Nm
❑
ss o
cial p
f
7 - Intake manifold
inform
mer
❑ With intake manifold
atio
flap motor - V157- and
om
intake manifold flap po‐ n

c
i
or
n
tentiometer - G336- .
thi
te
sd
va
❑ Must not be dismantled.

i
o
pr
cum
r
fo

en
ng
t.
yi
⇒ page 258
Co
Cop py
t. rig
8 - Bracket
gh ht
pyri by
Vo
co
❑ For exhaust gas recircu‐
by lksw
cted agen
Prote
lation cooler change‐
AG.
over valve - N345- .

9 - 9 Nm
cooler changeover valve -
N345-
11 - Seal
❑ Renew
12 - 20 Nm
13 - Connecting pipe
❑ To exhaust gas recirculation cooler
14 - Clip, 5 Nm
❑ Renew
15 - Connection
❑ For exhaust gas recirculation
16 - 8 Nm
17 - Seal
❑ Renew

Sharan 2011 ➤
18 - Throttle valve module - J338-

❑ With throttle valve potentiometer - G69-
19 - 8 Nm
20 - 9 Nm
21 - Clip
4.2 Removing and installing throttle valve

module - J338-
Removing
– Remove noise insulation -1- ⇒ Rep. gr. 50 .
– Loosen hose clamps -1- and -2- and remove air hose.

– Free off coolantolkhose
swa -3-.
ge es n
ot g
V
by ua
– Releaserihose
se
d
clip -2-. ran
tee
ho
ut or
– Disconnect
ss
a electrical connector -1- on charge pressure asender
c
- G31- and remove air pipe.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Intake manifold 257

Sharan 2011 ➤

– Remove bolt -1- for dipstick guide tube.
– Unscrew bolts -arrows- and remove throttle valve module -
J338- .
Installing
page 256 .
Note
Renew O-ring.
4.3 Removing and installing intake manifold

♦ Socket Torx T 30 - T10405-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
WARNING
l purpos

nf
ercia

orm

m
atio
om
n in
or c
thi
te

sd
iva
o
r
rp
cu
– Remove noise insulation -1- ⇒ Rep. gr. 50 .

o
m
f
en
ng
t.
yi Co
– Remove air intake hose. To do this, loosen hose clip -2-. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤

– Loosen hose clip -2- on throttle valve module - J338- , pull air
pipe off and leave in installation position.
– Disconnect electrical connectors at glow plugs ⇒ page 318 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o e
– Remove exhaust aut gas recirculation cooler changeover valve - or a
h
N345- -left arrow-
ss from bracket and lay aside. c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure
line. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Remove fuel rail ⇒ page 252 . d by ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Separate electrical connector -2- on throttle valve module -
J338- .
rrectne
– Remove bolt -1- for dipstick guide tube.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
– Open and remove clamp -1-. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
ise nte
thor Sharan e o 2011 ➤
u ra
4-cylinder common
ss a rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
c
ce
le
un
pt
– Unscrew bolts -arrows- for intake manifold diagonally from
an
d
itte
y li
outside to inside using socket T30 - T10405- .
erm
ab
ility
ot p
– Carefully remove intake manifold.
wit
is n
h re
Installing
ole,
spec
t to the co
page 256 .
rrectnes
Note
s o
cial p
f inform
Renew gaskets.
mer
atio
om
– Tighten intake manifold bolts from inside out in diagonal se‐
n
c
i
or
n
quence.
thi
te
sd
va
– Install air pipe.

i
o
pr
cum
r
fo
en
ng
– Install fuel rail ⇒ page 252 .

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
5 Air filter
⇒ “5.1 Assembly overview - air filter”, page 262
⇒ “5.2 Removing and installing air filter housing”, page 263
⇒ “5.3 Removing and installing air mass meter G70 ”, page 265
5.1 Assembly overview - air filter
1 - Hose connection
2 - Air intake hose
❑ To turbocharger
❑ Check for soiling and
leaves. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
3 - 1.5 Nm d b ua
ran
ir se tee
❑ Qty. 2 autho
or
ac
ss
4 - Air mass meter - G70-
ce
e
nl
pt
du
an
itte
y li
⇒ page 265
erm
ab
ility
ot p
5 - O-ring
wit
, is n
❑ Renew
h re
hole
spec
❑ Install with silicone-free
es, in part or in w
lubricant.
t to the co
6 - 1.5 Nm
❑ For upper part of air fil‐
rrectness of i
ter.
l purpos
7 - 8 Nm
❑ For air filter lower part
nform
ercia
8 - Sleeve
m
at
om
i
9 - Washer
on
c
in t
or
10 - Air filter upper part

his
ate
do
riv
❑ Remove dirt, leaves and

p
cum
or
salt residues
f
en
ng
t.
yi Co
11 - Air filter element Cop py
t. rig
gh
❑ Always use genuine
ht
pyri by
Vo
o
part for air filter element
c by lksw
cted agen
Prote AG.
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 808
12 - Air filter lower part
❑ Remove dirt, leaves and salt residues
❑ For cold countries, an air filter lower part is installed with a hose for hot air intake.
❑ Country-specific version: With snow screen.
13 - Connection for water drain hose
❑ Cleaning
14 - Water drain hose
❑ Cleaning
15 - Flutter valve
❑ Cleaning and reinstalling.

Sharan 2011 ➤
16 - Intake air guide

❑ To lock carrier.
❑ Remove dirt, leaves and salt residues
17 - Spring-type clip
❑ To turbocharger
5.2 Removing and installing air filter hous‐

ing
Removing
– Release retaining clips on sides -arrows- and pull off air duct
cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
– Release retaining clips on left and right -arrow A- and remove

un
pt
lower air duct -2-.

an
d
itte
y li
rm
ab
– Detach lower air duct at mounting brackets -3-; swing lower air
pe
ility
duct backwards slightly for this.

ot
wit
, is n
h re
– Detach air pipe -1- from lower air duct -arrow B-.
hole
spec
– Detach electrical connector -1- from air mass meter - G70- and
es, in part or in w
t to the co
pull off hose -2-.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5. Air filter 263

Sharan 2011 ➤
– Loosen hose clip -4- and remove air hose.

– Unscrew bolt -3- and remove air filter housing.
Installing
⇒ “5.1 Assembly overview - air filter”, page 262 .
Note
♦ Use a silicone-free lubricant when installing the air hose.
♦ Secure all hose connections with the same typen of
AGhose clips
. Volkswagen A
as original equipment ⇒ Electronic partsolcatalogue
ksw
age . G do
es n
ot g
yV ua
db ran
rise tee
tho
– Disconnect water drain hose -arrow-
au from air filter lower part or
ac
s
and clean dirt and leaves from
s connection and hose.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
5.3 Removing and installing air mass meter

- G70-
Removing
– Carefully pull air mass meter - G70- out of guide on air filter
housing.
Installing
⇒ “5.1 Assembly overview - air filter”, page 262 .
To ensure the proper function of the air mass meter - G70- it is
important to adhere to the following work sequences.
Note
♦ If the air filter element is very dirty or wet, particles of dirt or

water may reach the air mass meter and falsify the measured
air mass value. This would lead to loss of power, since a
smaller injection quantity is calculated.
n AG. Volkswagen A
♦ Always use genuineolkpart
swa for air filter element.
ge G do
es n
o V t gu
by
♦ Always renew
ris seal if damaged (infiltrating air).
ara
ed nte
tho eo
♦ Use a silicone-free
ss
au lubricant when installing the air hose and ra
c
seal.
ce
e
nl
pt
du
an
itte
y li

erm
ab
ility
ot p
wit
, is n

h re
hole
spec
– Check for salt residue, dirt and leaves in air mass meter and
es, in part or in w
t to the co
air intake hose (engine intake side).

– Check for contamination of intake duct as far as air filter ele‐
ment. If contamination is found, remove salt residues, dirt and
rrectness of i
leaves from top and bottom part of air filter housing by rinsing
l purpos
out or using a vacuum cleaner if necessary.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Air filter 265

Sharan 2011 ➤
6 Lambda probe and pressure differen‐

tial sender
⇒ “6.1 Removing and installing Lambda probe G39 with Lambda
probe heater Z19 ”, page 266
⇒ “6.2 Removing and installing pressure differential sender G505
”, page 267
6.1 Removing and installing Lambda probe

- G39- with Lambda probe heater - Z19-
en AG. V
olkswagen AG
ag does
ksw not
♦ Lambda probe open ring spanner Vol
by set - 3337- gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos

– Disconnect electrical connectors 3 - G39- for nf
ercia
-Lambda probe-.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Unscrew Lambda probe - G39- -3- using tool from Lambda

probe open ring spanner set - 3337- .
Installing
• Specified torque ⇒ page 272
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by
♦ Threads of new Lambda probes arerisalready
ed coated with as‐ ara
nte
sembly paste; the paste must not get
ut into the slots on the probe
ho eo
ra
body. ss a c
ce
le
♦ In the case of a used Lambda probe, grease only the thread

un
pt
an
d
with high-temperature paste. Do not allow any paste to enter

itte
y li
the slots on the probe body. High-temperature paste ⇒ Elec‐
rm
ab
pe
ility
tronic Parts Catalogue .
ot
wit
, is n
♦ When installing, the Lambda probe's electrical wiring connec‐
h re
hole
tion must always be re-attached in the same locations to
spec
prevent the Lambda probe cable from coming into contact with
es, in part or in w
t to the co
the exhaust pipe.
rrectness of i
6.2 Removing and installing pressure differ‐
ential sender - G505-
l purpos
Pressure differential sender - G505- determines charge status of
nform
ercia
particulate filter.
m
a
Removing
com
tion in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Lambda probe and pressure differential sender 267

Sharan 2011 ➤

– Remove bolts -3- and -4-, pull pressure differential sender -
G505- from bracket -arrow-.
– Remove retaining clips from both hoses.
– Carefully pull hoses straight off connections (connections
break off pressure sensor very easily).
AG. Volkswagen AG d
Installing agen oes
olksw not
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d b ar
Install in reverse order
orise of removal, observing the following. ante
th eo
s au ⇒ page 272
ra
c
s
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
♦ Before installing, blow out control lines of pressure differential
wit
is n
sender - G505- to particulate filter with compressed air to‐
h re
ole,
wards particulate filter (blocked or iced up due to condensa‐
spec
tion).
t to the co
♦ Make sure that hoses are securely fitted and seal properly.
♦ If pressure hoses have been detached from particulate filter,
rrectne
tighten ⇒ page 272 .
s
An adaptation must be performed after renewing pressure differ‐
s o
cial p
ential sender - G505- and/or particulate filter. (The procedure is

also described under Guided Functions). f inform
mer
atio
Select the correct vehicle in Guided Fault Finding.

om
n
c
i
or
– Press “GoTo” button.

thi
te
sd
va
– Press “Function/component selection”.

i
o
pr
cum
r
fo
– Select “Drive train”.

en
ng
t.
yi Co
op py
– “01 - Self-diagnosis compatible systems” t. C rig
gh ht
pyri by
– “01 - Engine electronics J623”
co Vo
by lksw
cted agen
Prote AG.
– Select “01 - Functions of engine electronics”
– “01 - Resetting learnt values (Rep. Gr. 21 - 28)”

Sharan 2011 ➤
7 Engine (motor) control unit

⇒ “7.1 Removing and installing engine (motor) control unit J623
”, page 269
⇒ “7.2 Removing and installing anti-theft engine control unit J623
”, page 270
7.1 Removing and installing engine (motor)

control unit - J623-
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
92 ; Windscreen wiper system; Removing and installing wiper
arms .
– Raise engine control unit -1- in front area in
-direction of arrow-.
– Pull engine control unit forwards out of the side guides -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Slide connector locking devices -1- on engine control ut unit in
ho eo
ra
-direction of arrow- and pull off both connectors. ss a c
ce
e
nl
Installing
pt
du
an
itte
y li
Specified torque of securing nuts for retaining frame: 6 Nm.
erm
ab
ility
ot p
– Attach connectors to engine control unit and slide locking de‐ wit
, is n
vices inwards until they engage. h re

hole
spec
es, in part or in w
t to the co
rrectness of i
– Push engine control unit -1- into side guides

l purpos
– Install plenum chamber bulkhead ⇒ General body repairs;
nf
ercia
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

rm
m
atio
m
– Install windscreen wiper arms ⇒ Electrical system; Rep. gr.

o
n in
c

or
thi
e
arms
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Engine (motor) control unit 269

Sharan 2011 ➤
7.2 Removing and installing anti-theft en‐

gine control unit - J623-
♦ Grip pliers
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
arms .
– Raise engine control unit -1- in front area in
– Pull engine control unit forwards out of the side guides -2-.
– Bend upwardly projecting tabs -1- of locking bar outwards.

olkswagen AG
en AG. V
– Unscrew shear-head bolts -2- using a pair oofkspliers
wag and remove does
not
V l
locking bar -3-. ed
by gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Slide connector locking devices -1- on engine control unit in

-direction of arrow- and pull off both connectors.
rrectness of i
Installing
l purpos
Specified torque of securing nuts for retaining frame: 6 Nm.

– Attach connectors to engine control unit and slide locking de‐
nf
ercia
vices inwards until they engage.

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Screw on a new locking bar -3- with new shear-head bolts

-2- and tighten bolts uniformly until just before heads shear off.
– Push engine control unit -1- into side guides

– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install windscreen wiper arms ⇒ Electrical system; Rep. gr.
arms
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Engine (motor) control unit 271

Sharan 2011 ➤
26 – Exhaust system
1 Front exhaust pipe with particulate fil‐
ter
⇒ “1.1 Assembly overview - front exhaust pipe with particulate
filter”, page 272
⇒ “1.2 Removing and installing particulate filter”, page 274
1.1 Assembly overview - front exhaust pipe

with particulate filter
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamping sleeve and align si‐
lencer and exhaust end pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded. . Volkswagen AG
gen AG does
swa
♦ Renew self-locking nuts. yV
olk not
gu
d b ara
e
♦ The decoupling element of the front exhaust pipethmust
oris be se‐ nte
eo
cured with transportation lock - T10404- to stops aoverstretch‐
u ra
c
ing. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
♦ Lambda probe open ring spanner set - 3337-
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
♦ Transport lock - T10404-

or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
272 Rep. gr.26 - Exhaust system

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Sharan 2011 ➤
ise nte
r
4-cylinderutcommon rail engine (2.0 l, EA189 Gen II) - Edition
ho eo
r a 10.2018
s a c
s
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
If particulate filter or pressure differential sender - G505- is ex‐
wit
, is n
changed, pressure differential sender - G505- must be adapted
h re
using vehicle diagnostic tester as a matter of priority: Guided
hole
spec
Functions; Adapting pressure differential sender - G505- .
es, in part or in w
t to the co
1 - Pressure differential sender
rrectness of i
- G505-
l purpos
⇒ page 267
2 - 10 Nm
nf
ercia
orm
3 - Shield
m
atio
om
n in
c
4 - Lambda probe - G39-

or
thi
e
❑ 50 Nm
t
sd
iva
o
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rp
cu
❑ Grease only thread with
o
m
f
high-temperature paste
en
ng
t.
yi
- G 052 112 A3- . Do not
Co
Cop py
allow high-temperature
t. rig
gh ht
yri
paste - G 052 112 A3- to p by
o Vo
by c lksw
get into slots of probe Prote
cted agen
body.
AG.

⇒ page 266
5 - Exhaust gas temperature
sender 4 - G648-
❑ 60 Nm
❑ Thread of sender is
coated.
grease.
6 - Seal
❑ Renew
sition
7 - Clip, 7 Nm
❑ Renew
sender 3 - G495-
❑ 60 Nm
❑ Thread of sender is coated.
❑ Do not additionally oil or grease.
9 - 25 Nm
10 - Mounting
11 - Particulate filter
❑ With oxidation catalytic converter and front exhaust pipe.
❑ After renewing, the adaption of ash mass comparison must be set to zero with the vehicle diagnostic
tester under “Guided functions”.
1. Front exhaust pipe with particulate filter 273

Sharan 2011 ➤
12 - 25 Nm
13 - Bracket
❑ Bolted to cylinder head.
14 - Control line, 45 Nm
❑ If not fitted, seal with dummy plugs.
15 - Bracket
❑ Bolted to diesel particulate filter
16 - Clip
❑ Renew
17 - Bracket
❑ Bolted to cylinder head.
18 - 25 Nm
19 - 8 Nm
20 - 25 Nm
1.2 Removing and installing particulate filter

⇒ “1.2.1 Vehicles with front-wheel drive”, page 274
⇒ “1.2.2 Vehicles with all-wheel drive”, page 279
G. Volkswagen AG d
1.2.1 Vehicles with front-wheel
olks
wdrive
agen
A
oes
not
V gu
by ara
Special tools and workshop equipment
ris required
ed nte
ho eo
ut
♦ -3253/5- from assembly toolss-a3253- ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Flange bolt M10x35

nform
ercia
♦ Lambda probe open ring spanner set - 3337-

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
ksw
agen oes
not
Sharan 2011 ➤
ol
4-cylinder common byV rail engine (2.0 l, EA189 Gen gu II) - Edition 10.2018
a
ed ran
ris tee
ho
♦ Ring ratchet spanner, 13 mm AF s-auT10384-
t or
ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Tool set - T10395-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Transportation lock - T10404-

Removing
– Remove Lambda probe ⇒ Rep. gr. 23 .
– Separate connectors for exhaust temperature sender 1 -
G235- -1-, for Lambda probe - G39- -3- and for exhaust
sender 4 - G648- .
– Guide lines out of brackets on plenum chamber bulkhead and
on turbocharger.

Sharan 2011 ➤
– Loosen bolt -2- and remove clamp.

– Open clip of differential pressure line on particulate filter and
pull off differential pressure line.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Undo and remove bolt -1- in upper bracket of particulate filter.
hole
spec
– Remove front right wheel.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
– Unscrew bolts -arrows- and remove heat shield for right drive
a
do
riv
shaft.
p
cum
for
en
ng
– Disconnect right drive shaft from gearbox flange ⇒ Running

t.
yi Co
op
gear, axles, steering; Rep. gr. 40 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Press right drive shaft downwards.

– Unscrew bolts -2- and -3- of pendulum support.

Sharan 2011 ➤
– Press engine/gearbox assembly to lock carrier and support

using pendulum support as shown in illustration.
A - Flange bolt M10x35
– Unscrew exhaust temperature sender 4 - G648- -item 1- from

exhaust pipe downstream of particulate filter using tool set 17
mm - T10395- .
Caution
Risk of damage to flexible joint

wage es n
♦ The flexible joint must be secured
by
Vol with transportation lock
ks ot g
ua
- T10404- -arrow-. ris
ed ran
tee
tho or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Unscrew nuts -1- and -2-. Nuts -1- can be reached with ratchet
ility
ot p
wrench 13 mm - T10384- .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Remove particulate filter bracket.

m
atio
om
n in
or c
Caution
thi
te
sd
iva
o
r
rp
cu
Make sure that the supply line leading to injector for reducing
o
m
f
en
ng
agent - N474- is not kinked.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
– Remove reducing agent injector - N474-
co lksw
by
cted agen
⇒ Item 9 (page 291) from reduction catalytic converter and Prote AG.
attach to body with cable ties or similar.

Sharan 2011 ➤
– Remove nuts -arrows- of underbody cladding.

– Remove NOx sender 2 control unit - J881- under underbody
panel on left.
– Remove nuts ⇒ Item 4 (page 291) on flange of reduction cat‐
alytic converter.
– Loosen nuts on clamp to silencer and push clamp to rear.
– Remove tunnel bridge ⇒ Item 10 (page 291) and remove re‐
duction catalytic converter.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Remove bolts -arrows- of bracket.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unscrew clamping washers -2- and -3-.

m
a
com
tion in
– Lower underbody panels on inner side until heat shield -1- can
r
te o
be removed.
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Remove coolant pipe of auxiliary heater (if fitted) from brackets

-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Remove particulate filter by turning 180° around its own axis. s
ce
le
un
pt
Installing
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ Renew seals, self-locking nuts and clip for particulate filter.
rrectne
♦ Fit all cable ties in the original position when installing.
ss o
– Observe sequence when installing particulate filter:
cial p
f inform
mer
1) Position particulate filter on turbo charger and loosely at‐
atio
tach clip -1-
om
n
c
i
2) Screw in bolts -2 … 5- loosely by hand
or
n thi
e
• It must still be possible to move particulate filter and

t
sd
va
bracket
i
o
pr
cum
r
fo
en
ng
t.
3) Tighten clip -1-
yi Co
Cop py
t. rig
4) Tighten bolts -2- and -5-. opyri
gh by
Vo
ht
5) Tighten bolts -3- and -4-.

c by lksw
cted agen
Prote AG.
– Installing exhaust temperature sender 4 - G648-
⇒ page 285 .
– Install reduction catalytic converter ⇒ page 290 .
– Align exhaust system free of stress ⇒ page 283 .
– Installing Lambda probe - G39- and pressure differential send‐
er - G505- ⇒ Rep. gr. 23 .
– After renewing particulate filter, carry out adaptation in “guided
functions” mode ⇒ Vehicle diagnostic tester.
1.2.2 Vehicles with all-wheel drive


Sharan 2011 ➤
♦ -3253/5- from assembly tool - 3253-
♦ Flange bolt M10x35

Removing AG. Volkswagen AG d
agen oes
olksw not
– Remove Lambda probe ⇒ Rep. gr. d by V23 . gu
ara
rise nte
– Separate connectors for exhaust
uth o temperature sender 1 - eo
ra
G235- -1-, for Lambda probe
ss a
- G39- -3- and for exhaust c
ce
e
nl
pt
sender 4 - G648- .
du
an
itte
y li
erm
ab
ility
ot p
– Guide lines out of brackets on plenum chamber bulkhead and
wit
, is n
on turbocharger.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Loosen bolt -2- and remove clamp.
l purpos
– Open clip of differential pressure line on particulate filter and

pull off differential pressure line.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Undo and remove bolt -1- in upper bracket of particulate filter.
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe with steering .
– Disconnect right drive shaft from gearbox flange ⇒ Running
gear, axles, steering; Rep. gr. 40 .
– Press right drive shaft downwards.

lkswage es n
o ot g
byV ua
ir se
d ran
te Sharan 2011 ➤
o
auth 4-cylinder common rail engine (2.0e ol,r aEA189 Gen II) - Edition 10.2018
ss c
ce
e
nl
pt
du
an
exhaust pipe downstream of particulate filter using tool set 17
itte
y li
mm - T10395- .
erm
ab
ility
ot p
– Unscrew nuts -1- and -2-. Nuts -1- can be reached with ratchet
wit
, is n
wrench 13 mm - T10384- .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove particulate filter bracket.
nform
mercia
at
om
Caution
ion
c
in t
or
his
e
Risk of damage to flexible joint.

at
do
priv
c
♦ Secure flexible joint with transportation lock - T10404- .
um
for
en
ng
t.
yi Co
Cop py
t. rig
– Remove nuts ⇒ Item 4 (page 291) on flange of reduction cat‐
gh ht
pyri by
alytic converter.
co Vo
by lksw
cted agen
Prote AG.
– Carefully remove particulate filter downwards.
Installing
Note
♦ Renew seals, self-locking nuts and clip for particulate filter.

♦ Fit all cable ties in the original position when installing.
– Observe sequence when installing particulate filter:

1) Position particulate filter on turbo charger and loosely at‐
tach clip -1-
2) Screw in bolts -2 … 5- loosely by hand
• It must still be possible to move particulate filter and
bracket
3) Tighten clip -1-

– Installing exhaust temperature sender 4 - G648-
⇒ page 285 .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe with steering .
– Installing Lambda probe - G39- and pressure differential send‐
er - G505- ⇒ Rep. gr. 23 .
– After renewing particulate filter, carry out adaptation in “guided
functions” mode ⇒ Vehicle diagnostic tester.

Sharan 2011 ➤ gen AG
. Volkswagen AG
does
swa
4-cylinder common
y Vrail engine (2.0 l, EA189 Gen II)
olk not - Edition 10.2018
gu b ara
ed nte
oris e
th or
au
2 Silencer
ss
ac
ce
e
nl
pt
du
⇒ “2.1 Assembly overview - silencers”, page 282
an
itte
y li
erm
ab
⇒ “2.2 Aligning exhaust system free of stress”, page 283
ility
ot p
⇒ “2.3 Installation position and specified torque of clamp”,
wit
, is n
h re
page 283
hole
spec
es, in part or in w
t to the co
Note
♦ After working on the exhaust system, ensure that the system
rrectness of i
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamping sleeve and align si‐
l purpos
lencer and exhaust pipe so that sufficient clearance is main‐

tained to the bodywork and the support rings are evenly
nf
ercia
loaded.
orm
m
♦ Renew self-locking nuts.
atio
om
n in
or c
thi
2.1 Assembly overview - silencers
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
1 - From reduction catalytic

t.
yi Co
op
converter
C py
ht. rig
rig ht
py by
2 - Clamping sleeve co Vo
by lksw
cted agen
❑ Installation position and Prote AG.
specified torque
⇒ page 283
3 - Rear silencer
❑ Aligning exhaust sys‐
tem free of tension
⇒ page 283 .
4 - Mounting
❑ With retaining ring
5 - 25 Nm
6 - Mounting

Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189
en AG. Gen
VolkswII)
a g -
enEdition
AG 10.2018
ag does
ksw not
y Vol gu
2.2 Aligning exhaust system free of stress
b ara
ed nte
oris eo
th
• Engine must be cold au ra
c
ss
ce
le
– Loosen bolts -3 and 4- on front clamp -1-.
un
pt
an
d
itte
y li
– Align front clamp -1- to marking -A- on front exhaust pipe -2-
rm
ab
(-arrow- points forwards).
pe
ility
ot
wit
, is n
• Dimension -a- = ⇒ page 283
h re
hole
spec
• Do not allow the bolts must be on the right and the ends to
es, in part or in w
protrude beyond the lower edge of the clamp.
t to the co
rrectness of i
l purpos
– Push rear silencer forwards into clamp until dimension -a-
nform
ercia
15…17 mm is attained between mountings for body and rear

m
silencer. -Arrow- points in direction of travel.
a
com
tion in
– Align rear silencer horizontally.
r
te o
thi
s
iva
– Tighten clamp bolts in this position. Mounting position and
do
r
rp
c
specified torque ⇒ page 283 .
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.3 Installation position and specified torque

of clamp
Note
Gradual introduction of clamp with continuous clip.
Specified torque and installation dimensions of clamp

Clamp -A- with 2 individual clips.
Specified torque 25 Nm
Installation dimensions -a- 5 mm (only for front clamp)
Clamp -B- with continuous clip.
Specified torque 35 Nm
Installation dimensions -a- 8.5 mm (only for front clamp)
2. Silencer 283
Sharan 2011 ➤
Installation dimension -a- for vehicles with marking on front ex‐

haust pipe
1 - Clamping sleeve
2 - Front exhaust pipe
a - Installation dimension
A - Marking
Installation position of front clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
AG. Volkswagen AG d
• Threaded connection faces right olksw
agen oes
not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Installation position of rear clamp
hole
spec
– Install clamp so that end of bolt -arrow- does not extend be‐
es, in part or in w
t to the co
yond lower edge of clamp.
• Threaded connection faces to rear.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
3 Exhaust gas temperature regulation

⇒ “3.1 Assembly overview - exhaust gas temperature regulation”,
page 285
⇒ “3.2 Removing and installing exhaust gas temperature sender
1 G235 ”, page 286
3 G495 ”, page 287
4 G648 ”, page 289
3.1 Assembly overview - exhaust gas tem‐

perature regulation
Caution
Threads of exhaust gas temperature sender -G495- and -

G648- are coated. Do NOT additionally grease with high-
temperature paste and always adhere to the prescribed
tightening torque. Otherwise, the threaded connection can be‐
come loose and subsequent failures can then occur.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
1- Exhaust turbocharger
rise
d
nte
tho eo
2- Control
ss a line, 45 Nm
u ra
c
❑ If not fitted, seal with
ce
le
un
pt
dummy plugs.
an
d
itte
y li
rm
ab
pe
ility
ot
4 - 9 Nm
wit
, is n
h re
hole
5 - Bracket
spec
es, in part or in w
❑ Bolted to diesel particu‐

t to the co
late filter
6 - Hose
rrectness of i
7 - Bracket
l purpos
❑ For pressure differential

sender - G505- .
nform
ercia
8 - Pressure differential sender

- G505-
m
a
com
tio

n in
r
⇒ Rep. gr. 23
te o
thi
s
iva
do
9 - Bracket
r
rp
cum
fo
en
10 - 4.5 Nm
ng
t.
yi Co
op py
11 - 8 Nm t. C rig
gh ht
yri by
❑ cop Vo
by lksw
cted agen
Prote
AG.
sender 3 - G495- , 60 Nm
⇒ page 287
❑ Thread of sender is
coated.
grease.
3. Exhaust gas temperature regulation 285

Sharan 2011 ➤
13 - Lambda probe - G39- with Lambda

gen AG
. Volkswaprobe
gen AG heater - Z19-
swa does
❑ Removing andy Vinstalling ⇒ Rep. gr. 23
olk not
gu
e an db ar
14 - Exhaust gas
tho temperature sender 4 - G648- , 60 Nm
ris tee
or
u
❑ Removing
ss
a
and installing ⇒ page 289 ac
ce
le
❑ Thread of sender is coated.

un
pt
an
d
itte
❑ Do not additionally oil or grease.
y li
erm
ab
15 - Exhaust gas temperature sender 1 - G235- , 45 Nm
ility
ot p
wit
is n
h re
ole,
❑ Coat with high-temperature paste; high-temperature paste ⇒ Electronic parts catalogue .
spec
t to the co
3.2 Removing and installing exhaust gas
rrectne
temperature sender 1 - G235-
ss o
cial p
f
♦ Tool insert, AF 17 mm - T10395-
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Separate electrical connector -1- for exhaust temperature
sender 1 - G235- and move electrical wire aside.

Sharan 2011 ➤
Note
Threaded connection is accessible from below.

exhaust manifold.
Installing
⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 285 .
Note
♦ Coat threads of exhaust temperature sender with high-tem‐

perature paste; high-temperature paste ⇒ Electronic Parts
Catalogue . n AG. Volkswagen AG ge does
swa
♦ Fit all cable ties
by in the original position when installing.
Vol
k not
gu
a
ed ran
oris tee
h
Installation auposition
t
of exhaust gas temperature sender -G235-
or
ac .
ss
ce
e
nl
pt
• Angled shaft must have a distance -a- = 3 … 5 mm to bolting

du
an
itte
of turbocharger support.
y li
erm
ab
ility

ot p

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia

orm

m
atio
om
n in
or c
thi
e
Caution
t
sd
iva
o
r
rp
cu
o

f
en
ng
t.
yi
Co
op py
t. C rig
gh ht
yri
specified torque ⇒ page 285 . Otherwise, the threaded con‐
p by
co Vo
nection can become loose and subsequent failures can then
by lksw
cted agen
Prote
occur.
AG.

Sharan 2011 ➤
Removing
– Remove Lambda probe - G39- ⇒ page 266 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Unscrew exhaust temperature sender 3 - G495- -item 1-.
erm
ab
ility
ot p
Installing
wit
, is n
h re
hole
spec
es, in part or in w
tion”, page 285 .
t to the co
rrectness of i
Note
l purpos
Fit all cable ties in the original position when installing. nform
mercia
at
om
Installation position of exhaust temperature sender 3 - G495-

ion
c
-item 1-:
in t
or
his
ate
• Angled end facing left side of vehicle.

do
priv
cum
or
• Angle -α- to mark -arrow- = approx. 17°.

f
en
ng
t.
yi Co
op
• Specified torque ⇒ page 285 C py
t. rig
gh ht
yri
– Install Lambda probe - G39- ⇒ page 266 .
p by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤

Caution

specified torque ⇒ page 285 . Otherwise, the threaded con‐
nection can become loose and subsequent failures can then
occur.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Removing
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-

n
t.
yi Co
from exhaust pipe downstream of particulate filter. Cop py
t. rig
gh ht
yri
Installing p by
o Vo
by c lksw
cted agen
• Specified torque Prote AG.

tion”, page 285 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Sharan
autho
2011 ➤ eo
ra
4-cylinder
ss common rail engine (2.0 l, EA189 Gen II) -c Edition 10.2018
ce
e
nl
pt
du
an
itte
y li
4 SCR system (selective catalytic re‐
erm
ab
ility
ot p
duction)
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ To keep the following description as short as possible, the
“NOx reducing agent AUS 32” (AdBlue®) is just called “reduc‐
rrectness of i
ing agent”.
l purpos
♦ The design and function of the SCR systems is described in

⇒ Self-study programme No. 424 ; Selective Catalytic Re‐
nf
ercia
duction .
orm
m
atio
om
n in
c
WARNING
or
thi
te
sd
iva
o
♦ The reducing agent can irritate skin, eyes and respiratory
r
rp
cu
o
m
organs.
f
en
ng
t.
yi Co
op
♦ In the event of skin contact with this fluid, immediately C py
t. rig
wash off with plenty of water.
gh ht
pyri by
Vo
co lksw
by
♦ Seek medical attention if necessary. Prote
cted AG.
agen
⇒ “4.1 Assembly overview - reduction catalytic converter”,

page 290
⇒ “4.2 Assembly overview - tank for reducing agent”, page 292
⇒ “4.3 Removing and installing heater element (heater cup)”,
page 293
⇒ “4.4 Removing and installing injector for reduction agent N474
”, page 297
⇒ “4.5 Draining reducing agent tank”, page 298
⇒ “4.6 Removing and installing reducing agent tank”, page 300
4.1 Assembly overview - reduction catalytic converter

Sharan 2011 ➤
⇒ page 274
2 - Seal
❑ Renew
3 - 25 Nm
4 - 23 Nm
5 - Reduction catalytic convert‐
er
6 - NOx sender 2 - G687-
❑ 50 Nm
❑ With NOx sender 2 con‐
trol unit - J881- .
❑ Remove left underbody
panel in order to remove
and install.
7 - Clip, 5 Nm AG. Volkswagen AG d
agen oes
❑ Renew olksw not
byV gu
ara
ed
8 - Seal horis nte
eo
ut
❑ Renew ss a ra
c
ce
e
9 - Injector for reducing agent -

nl
pt
du
an
N474-
itte
y li
erm
ab
ility
ot p
⇒ page 297
wit
, is n
h re
10 - Tunnel cross-piece
hole
spec
11 - 25 Nm
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. SCR system (selective catalytic reduction) 291

Sharan 2011 ➤
4.2 Assembly overview - tank for reducing agent
1 - Wiring harness
2 - 5 Nm
3 - Pump for reducing agent -
V437-
❑ With heater for reducing
agent pump - Z103- .
❑ With pressure sender
for reducing agent me‐
tering system - G686- .
❑ With reversal valve for
reducing agent - N473- .
AG. Volkswagen AG d
agen oes
4 - Seal olksw not
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ara
ed
ris nte
ho eo
Caution
s aut ra
c
s
Various versions of
ce
le
un
pt
pump for reducing agent.
an
d
itte
The seal is not fitted on
y li
erm
ab
all versions. Observe
ility
ot p
note in ⇒ Electronic
wit
is n
Parts Catalogue !
h re
ole,
spec
❑ Renew
t to the co
5 - Seal
❑ Renew
rrectne
s
❑ Remove and install us‐

s o
ing wrench - T50014- .

cial p
f inform
7 - Breather connection
mer
atio
m
8 - Heater element (heater

o
n
c
cup)
or
n thi
te
sd
❑ With heater for reducing

iva
o
r
agent tank - Z102- .

p
cum
r
fo
en
ng
❑ With reducing agent level sender - G697-

t.
yi Co
op
❑ With temperature sender for reducing agent - G685-
C py
ht. rig
rig ht
py by
9 - Seal
co Vo
by lksw
cted agen
Prote AG.
10 - Filter
11 - Evaluation unit for reducing agent level - G698-
12 - 25 Nm
13 - Control unit for reducing agent heater - J891-
14 - Reducing agent tank
15 - Seal
16 - Cap
❑ For filling
❑ Accessible from luggage compartment

Sharan 2011 ➤
17 - Delivery line
❑ For reducing agent
❑ With heater for reducing agent line - Z104- .
18 - Injector for reducing agent - N474-
4.3 Removing and installing heater element

(heater cup)
Note
To keep the following description as short as possible, the “NOx

reducing agent AUS 32” (AdBlue®) is just called “reducing agent”.
WARNING

organs.
♦ In the event of skin contact with this fluid, immediately
♦ Seek medical attention if necessary.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
Removing ht. rig
rig ht
py by
o Vo
– Remove tank for reduction agent ⇒ page 300 . by c lksw
cted agen
Prote AG.

Sharan 2011 ➤
Caution
Protect separated electrical connections against wetting from

reducing agent by suitable means, e.g. plastic bag and cable
ties. Due to the high tendency to creep combined with subse‐
quent crystallisation of the reducing agent, the electrical con‐
nections can be damaged.
– Pull off connectors -arrows- at pump for reducing agent -

V437- .
Caution
Immediately seal all openings and connections using suitable

plugs to stop ingress of dirt. Even very small particles of dirt
can cause considerable damage to the system.
– Disconnect connectors -2- and -3-, remove securing bolts

-A- and pull pump for reduction agent - V437- out upwards.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Cut through cable ties -arrows- on locking ring and pull breath‐ ce
e
nl
pt
du
er line -1- off upwards. an

itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 2011 ➤
– Fit special wrench - T50014- onto locking ring as shown and

unscrew it.
Caution
When open, only tilt cover a max. of 30° this prevents damage
to electrical cables and suction probe of delivery module.
– Open cover of delivery module, if necessary use wedge -

3409- .
– Carefully grasp in cup of delivery module and release it from
the locking device by turning it anti-clockwise.
– Remove delivery module upwards out of tank for reduction
agent.
Installing
– Fit seal ⇒ Item 9 (page 292) to opening of tank for reduction
agent.
– Fit delivery module into tank for reduction agent, note mark‐
ings -A-. The marks -A- must align when inserting.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Carefully grasp insscup
au of delivery module and engage it by ac
turning it clockwise. The marks -B- must align when engaged
ce
le
un
correctly.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Moisten sealing pin of cover with water and press it carefully

ss o
into seal. The marks -1- must align.

cial p
f inform
– Fit locking ring and tighten it hand-tight.

mer
atio
om
n
c
Caution
i
or
n thi
te
sd
va
Ensure locking ring is not cross threaded on threads of tank for

i
o
pr
cum
r
reducing agent. If the locking ring does not sit properly, the
fo
en
ng
consequence will be leaks and considerable corrosion dam‐

t.
yi Co
op
age. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Fit special wrench - T50014- onto locking ring as shown and

tighten it. Specified torque ⇒ page 292 .
– Wash off excessive reduction agent using water.
– Secure cable ties -arrows- on locking ring and reconnect

breather line -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– When setting pumporise
for reducing agent - V437- in place, fit
nte
eo
spacer -2- ifaurequired.
th
ra
ss c
• If there is a casting -arrow- on the pump for reducing agent -
ce
e
nl
pt
du
V437- , do not fit the spacer -2-.

an
itte
y li
erm
• If there is no casting -arrow-, the spacer -2- must be fitted be‐

ab
ility
fore the seal-1-.

ot p
wit
, is n
• If there is a casting -arrow,-, fit only the seal -1-.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
– Fit pump for reduction agent - V437- , reconnect connectors

his
ate
-2- and -3-, tighten securing bolts -A-. Specified torque

do
priv
⇒ page 292 .
um
for
en
ng
t.
yi
– Reconnect connectors -arrows- on pump for reducing agent -
Co
op py
V437- and reconnect supply line -1-.
t. C rig
gh ht
pyri by
Vo
o
– Install tank for reduction agent ⇒ page 300 . by c lksw
cted agen
Prote AG.
– Check for leaks ⇒ Vehicle diagnostic tester.

Sharan 2011 ➤
4.4 Removing and installing injector for re‐

duction agent - N474-
Note

WARNING

organs.
Removing
Caution
G. Volkswagen AG d
Protect separated electrical connections against wetting from wage
nA oes
olks not
reducing agent by suitable means, e.g. plastic bag and bycable
V gu
ara
ties. Due to the high tendency to creep combined with oris subse‐
ed nte
quent crystallisation of the reducing agent, the electrical
au
th con‐ eo
ra
nections can be damaged. ss c
ce
e
nl
pt
du
an
itte
y li
– Disconnect electrical connector on injector for reduction agent
erm
ab
- N474- .
ility
ot p
wit
, is n
– First press securing clip for line connection on injector for re‐
h re
duction agent - N474- together in direction of -arrow 1.- as
hole
spec
shown, and pull off delivery line in direction of -arrow 2.- with‐
es, in part or in w
out tools and without »jerking«.
t to the co
Caution
rrectness of i
l purpos

nf
ercia
orm
m
atio
m
– Open clip ⇒ Item 7 (page 291) and remove injector for reducing
o
n in
c
agent - N474- .
or
thi
te
sd
a
Installing
iv
o
r
rp
cu
o
– Install injector for reduction agent - N474- with a new sealing

f
en
ng
t.
yi
washer, observing lug on reducer catalytic converter (electri‐
Co
op py
cal connector faces upwards). t. C rig
gh ht
pyri by
Vo
– Place new securing clamp over connection and press it to‐
co lksw
by
cted agen
gether until it engages. This action locates the injector for Prote AG.
reducing agent - N474- .
– Fit bolt and tighten to prescribed torque ⇒ Item 7 (page 291) .
– First reconnect electrical connector, then reconnect delivery
line.

Sharan 2011 ➤
4.5 Draining reducing agent tank
Note

WARNING

organs.

♦ Vacuum box - VAS 6557-
Note
AG. Volkswagen AG d
agen oes
Tank for reducing agent is emptied via filler neck.
yV
olks
w not
gu
b ara
ed nte
oris eo
th
au ra
Caution ss c
ce
e
nl
pt
du
Always ensure that no reducing agent contacts clothing or

an
itte
y li
bodywork.
erm
ab
ility
ot p
If this occurs, wash out reducing agent using clear water and
wit
, is n
a lint-free cotton cloth.

h re
hole
spec
If the reducing agent has already crystallised, use warm water
es, in part or in w
and a sponge.
t to the co
Reducing agent that has not been removed will crystallise and
damage the surface after some time.
rrectness of i
Information concerning storage and disposal ⇒ ServiceNet →

l purpos
Environmental protection → Workshop disposal ! Request

country specific information concerning storage and disposal
from importer.
nf
ercia
orm
m
atio
m
Filler opening for tank for reducing agent is located in luggage

o
n in
c
compartment behind a cover.

or
thi
te
sd
iva
– Turn plug-in connector -1- clockwise and remove cover -2-.

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 2011 ➤
– Open cover of reducing agent tank -1-.

. Volkswagen AG
gen AG does
Prepare vacuum box - VAS 6557- as follows:
Vol
ksw
a
not
y gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Close shut-off taps -A-, -B- and -C-.
rrectness of i
Note
l purpos
In order to guide the extraction line -E- into the filler neck of the
reducing agent tank, the metal head of the line must first be re‐
nform
ercia
moved.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Connect coupling -D- with connection to shut-off tap -A- and
Co
op py
pressurize compressed air hose with compressed air.
t. C rig
gh ht
pyri by
Vo
o
– Open shut-off tap -A-. by c lksw
cted agen
Prote AG.
A vacuum is now created in the vacuum box - VAS 6557- .
– Close shut-off valve -A- as soon as the pressure gauge reg‐
isters a pressure of 0.8 bar.
– Disconnect coupling -D- from connection on shut-off tap -A-

and interrupt compressed air from compressed air hose.

Sharan 2011 ➤
– Guide end of hose -E- into filler neck to bottom of tank for re‐
duction agent then open shut-off tap -B-.
Note
The reducing agent is then drawn from the tank and into the vac‐
uum box - VAS 6557- by the vacuum. The capacity of the vacuum
box - VAS 6557- is 11 litres. This extracted volume is sufficient
for removal of the reducing agent tank. If the reducing agent tank
holds a greater amount and the tank is to be emptied, then repeat
the process.
– To empty the vacuum box - VAS 6557- , hold shut-off tap -C-
over a suitable container and open shut-off valves -A- and
-C-.
Caution
Extracted reducing agent must never be used again. Informa‐

tion concerning storage and disposal ⇒ ServiceNet → Envi‐
ronmental protection → Workshop disposal ! Request country
specific information concerning storage and disposal from im‐
porter.
– Flush out vacuum box - VAS 6557- carefully using water when
work sequence is complete.
4.6 Removing and installing reducing agent

tank AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Note horis nte
eo
aut ra
s c
To keep the following description as short as possible, the “NOx s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
WARNING
wit
, is n
h re
hole
spec
es, in part or in w
organs.
♦ In the event of skin contact with this fluid, immediately t to the co
rrectness of i

l purpos
Removing
nform
ercia
– Emptying tank for reduction agent ⇒ page 298 .

m
a
com
tio
– Remove rear bumper ⇒ General body repairs, exterior; Rep.

n in
r
te o
gr. 63 ; Bumpers .
thi
s
iva
do
– Release rear section of rear left wheel housing liner and push
r
rp
cum
fo
it forwards ⇒ General body repairs, exterior; Rep. gr. 66 ;

en
ng
t.
Wheel housing liner . Cop
yi Co
py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 2011 ➤
Caution

– Remove connector -A- from bracket and disconnect.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– First press securing clip for line connection -B- together in di‐
ility
ot p
rection of -arrow 1- as shown, and pull off delivery line in
wit
is n
direction of -arrow 2- without tools and without »jerking«.
h re
ole,
spec
Caution
t to the co
rrectne
ss
o
cial p
f i
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Disconnect connectors -arrows- from reducing agent tank. pyri by
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– Place engine and gearbox jack - V.A.G 1383 A- under reduc‐
itte
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ing agent tank.
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es, in part or in w
t to the co
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nform
ercia
– Remove seal of filler neck -1- in wheel housing from hole in

m
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tion in
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rig ht
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– Undo bolt -arrow- in area of rear axle.

Sharan 2011 ➤
AG. Volkswagen AG d
agen
4-cylinder common rail engineol(2.0
ksw l, EA189 Gen II) - Edition no 10.2018
oes
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– Remove bolts on side -arrows- and release lockingtholugs
ris
on left eo
and right next to bolts. au ra
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ss
ce
le
– Carefully lower reducing agent tank, taking care not to damage
un
pt
filler neck.
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Installing
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Note
hole
spec
es, in part or in w
t to the co
Ensure all components are installed on tank for reduction agent,
the upper insulation is fitting exactly and that no lines are squash‐
ed.
rrectness of i
– Carefully raise tank for reducing agent using engine and gear‐
l purpos
box jack - V.A.G 1383 A- until securing bolts can be fitted.
– Tighten securing bolts. Specified torque ⇒ page 292 .
nform
ercia
– Reconnect electrical wiring and delivery line, and clip them into
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respective retainers.
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– Install rear bumper ⇒ General body repairs, exterior; Rep. gr.
thi
s
iva
63 ; Bumpers .
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rp
cum
fo
– Install rear left wheel housing liner ⇒ General body repairs,
en
ng
t.
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exterior; Rep. gr. 66 ; Wheel housing liner .
Co
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t. rig
– Fill reducing agent tank ⇒ Maintenance ; Booklet .
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Sharan 2011 ➤
5 Exhaust gas recirculation system

⇒ “5.1 Assembly overview - exhaust gas recirculation”,
page 304
⇒ “5.2 Checking changeover for exhaust gas recirculation cooler”,
page 305
⇒ “5.3 Removing and installing exhaust gas recirculation cooler”,
page 305
⇒ “5.4 Checking exhaust gas recirculation cooler for leaks”, page
308
⇒ “5.5 Cleaning exhaust gas recirculation system”, page 312
5.1 Assembly overview - exhaust gas recirculation
1 - 9 Nm
pipe
of cracking
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3 - 9 Nm yV
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4 - Seal ir se tee
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❑ Renew ss
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5 - Vacuum line pt
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❑ Do not alter shape. y li

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6 - 9 Nm wit
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❑
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spec
7 - Seal
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❑ Renew
pipe
rrectness of i

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of cracking
nform
ercia
9 - 9 Nm
m
❑
at
om
ion
c
10 - Clip, 4 Nm
in t
or
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❑ Renew
a
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or

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cooler
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❑ With integrated exhaust
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gas recirculation valve - p by
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N18- with exhaust gas
by lksw
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recirculation potentiom‐
AG.
eter - G212- .
❑ Checking changeover ⇒ page 305 .
❑ Checking exhaust gas recirculation cooler for leaks ⇒ page 308
12 - 9 Nm
13 - Seal
❑ Renew

Sharan 2011 ➤
14 - Seal
❑ Renew AG. Volkswagen AG d
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15 - Exhaust gas recirculation pipe by V ol not
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❑ With flexible joint; do not bend
horis flexible joint - risk of cracking nte
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16 - 22 Nm ss c
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❑ Renew
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17 - 9 Nm
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18 - Seal
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❑ Renew
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spec
es, in part or in w
t to the co
5.2 Checking changeover for exhaust gas
recirculation cooler
rrectness of i
l purpos
♦ Hand operated vacuum pump - VAS 6213-
nform
mercia
a
com
tion in
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
Procedure
– Remove heat shield sleeve.
– Pull vacuum hose off vacuum unit and connect hand vacuum
pump - VAS 6213- .
– Operate hand vacuum pump to create a vacuum.
• The linkage of the changeover for the exhaust gas recircula‐
tion cooler must move -arrows-.
If linkage does not move or only moves in jerks:
♦ Vacuum actuator is defective.
♦ Changeover flap for exhaust gas recirculation is tight.
Note
Fit heat insulation sleeve in the original position when installing.
5.3 Removing and installing exhaust gas re‐

circulation cooler
5. Exhaust gas recirculation system 305

Sharan 2011 ➤
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
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Removing
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– Remove particulate filter ⇒ page 274 .

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Cop py
.
– Press release buttons and remove hose -1- for venting crank‐
ht rig
rig ht
by
case. copy Vo
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AG.
– Remove air pipe from air filter housing; release hose clip -3-
for this.

Sharan 2011 ➤

– Loosen hose clip -1- and remove pulsation damper -2-.
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– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
hole
spec
lation.
es, in part or in w
t to the co
– In vehicles with an auxiliary heater, remove the brackets for
the coolant lines leading to the auxiliary heater from the cylin‐
der block or transfer gearbox and the oil sump.
rrectness of i
Vehicles with front-wheel drive
l purpos
nform
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at
om
ion
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in t
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ate
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
do
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remove turbocharger support with oil supply line.

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Vehicles with all-wheel drive
yi Co
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– Remove right drive shaft ⇒ Running gear, axles, steering;
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Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
co Vo
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Prote AG.
– Pull right flange shaft from bevel box ⇒ Rep. gr. 39 ; Front
final drive, Assembly overview - front final drive .
– Unscrew bolts -1- and -3- and banjo bolt -4-.

– Open connection to oil supply line, separate support from oil
supply line and remove.

Sharan 2011 ➤
– Remove union nut -2- from turbocharger.

– Place drip tray - VAS 6208- beneath engine.
– Pinch off coolant hoses -1- and -3- with hose clamps -3094-
and remove from exhaust gas recirculation cooler; loosen
hose clamps for this.
– Remove vacuum hose -4- from vacuum unit and free.
– Unscrew bolts -arrows- and remove exhaust gas recirculation
cooler.
Installing
⇒ “5.1 Assembly overview - exhaust gas recirculation”,
page 304 .
– Adapting exhaust gas recirculation valve using vehicle diag‐
nostic tester : 01_Engine electronics , Guided func- agen
AG. Volkswagen AG d
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♦ Renew gaskets, seals and self-locking nuts.

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spec
es, in part or in w
t to the co
♦ Reinstall heat insulation sleeve in original position when in‐
stalling.
rrectness of i
– Installing support for turbocharger with oil supply line, inlet
connection and pulsation damper ⇒ page 205 .
l purpos
nform
ercia
– Install particulate filter ⇒ page 274 .

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– Check coolant level ⇒ page 159 .

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5.4 Checking exhaust gas recirculation

s
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cooler for leaks

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A pressure of 0.8 bar is applied to the exhaust side of the exhaust
gas recirculation cooler. While so, the pressure in the cooling
system is measured.

Sharan 2011 ➤
♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/11-

♦ Adapter - V.A.G 1687/15- for exhaust pipes of 60 mm and
65 mm in diameter
♦ Adapter - V.A.G 1687/16- for exhaust pipes of 55 mm in di‐
ameter
♦ Y-branch - VAS 691 005/1-
AG. Volkswagen AG d
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♦ Test adapter - VAS 691 005/5-
ility
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♦ Turbocharger tester - V.A.G 1397A-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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Test specification:
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• Coolant temperature must be at least 40°C.

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Sharan 2011 ➤
Connecting turbocharger tester - V.A.G 1397A- :

– Screw adapter - VAS 691 005/5- onto coolant expansion tank.
– Fit Y-branch - VAS 691 005/1- onto adapter - VAS 691 005/5- .
– Close valve -1- for connection »C«, and open valve -2- for
connection »A«.
– Connect hose from connection »A« of Y-branch to connection
»II« of turbocharger tester - V.A.G 1397A- .
– Set turbocharger tester - V.A.G 1397A- to switch position
»II« (gauge pressure measurement), and switch it on. The
setting »II« must be visible.
Connecting charge air system tester - V.A.G 1687- :

– If fitted, unclip wire to exhaust flap control unit -1-.
– Loosen clamp -2- on exhaust pipe, and push it towards rear.
. Volkswage
– On vehicles without a tunnel cross-piece, ksw
use
agen Aa
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tensioning
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– Connect adapter - V.A.G 1687/11- with hose -A- to exhaust

pipe (engine side). Secure hose with hose clips.
rrectness of i
Use hose -A- for exhaust pipes of 55 mm in diameter = hose

l purpos
- V.A.G 1687/16- .
Use hose -A- for exhaust pipes of 60 mm and 65 mm in diam‐
nform
ercia
eter = hose - V.A.G 1687/15- .

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– Connect charge air system tester - V.A.G 1687- to adapter -

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V.A.G 1687/11- .
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Sharan 2011 ➤
Prepare charge air system tester - V.A.G 1687- as follows:

– Completely unscrew pressure regulating valve -2-, close
valves -3- and -4-.
• To turn pressure regulating valve -2-, rotary knob must be
pulled upwards.
– Apply compressed air -1- to charge air system tester - V.A.G
1687- .
– Open valve -3-.

– Adjust pressure to 0.8 bar with pressure control valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.8 bar.
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Note d byV ua
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ir se tee
th o
or
A small amount of sair
s au
escapes through the valves and enters the ac
engine. Therefore a holding pressure test is not possible.
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pe
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Reading turbocharger tester - V.A.G 1397A- :
ot
wit
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• Observe turbocharger tester for approx. 5 minutes.

h re
hole
• The pressure indicated on the turbocharger tester must not spec

es, in part or in w
exceed 0.025 bar.

t to the co
– If the pressure on the turbocharger tester rises above

0.025 bar, compressed air is leaking from the exhaust side into
rrectness of i
the cooling system. The exhaust gas recirculation cooler has

a leak. Renew exhaust gas recirculation cooler.
l purpos
nform
ercia
Note
m
a
com
When coolant cools down, a vacuum may build up. The vacuum
ion in
is indicated by a »minus« symbol on the turbocharger tester .

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thi
Values preceded by a »minus« symbol do not indicate a leak! If

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iva
do
you are uncertain, equalise the pressure in the cooling system

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rp
cum
and repeat the test.

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Cleaning Y-branch - VAS 691 005/1- :
ht
pyri by
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Prote AG.
Note
After the leakage test has been completed, the Y-branch - VAS
691 005/1- must be cleaned and any moisture which may have
entered must be removed.
– Insert cleaning nozzle -D- into hose on connection -A- of Y

junction .
– Fit adapter - VAS 691 005/5- onto hose of connection -B-.
– Fit compressed air hose to connection -C-.
– Open shut-off taps, and blow out hose for approx. 15 seconds.

Sharan 2011 ➤
5.5 Cleaning exhaust gas recirculation sys‐

tem swa
gen AG
. Volkswagen AG
does
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♦ The exhaust gas recirculation module comprises the exhaust
nl
pt
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gas recirculation cooler and the exhaust gas recirculation
an
itte
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valve - N18- integrated in it. erm
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♦ It is only possible to perform the cleaning process on exhaust
wit
, is n
gas recirculation modules as of part number - 03L 131 512
h re
DQ/DP- .
hole
spec
es, in part or in w
♦ Before starting work, check the part number -1- using an en‐
t to the co
doscope (e.g. VAS 6748A/1).
♦ To do this, insert endoscope between cylinder head and ex‐
rrectness of i
haust manifold through opening in exhaust manifold -arrow-,
and guide it slightly towards right (seen in direction of travel).
l purpos
♦ For reasons of clarity, the particulate filter is not shown in the

lower section of the figure.
nform
mercia
Explanation
at
om
ion
c
With some extreme modes of driving (e.g. short journeys) there
in t
or
his
e
is a risk of varnish and coke deposits building up on the inside of

at
do
riv
the exhaust gas recirculation cooler. In this case, the exhaust

p
cum
or
emissions warning lamp lights up in the dash panel insert, and

f
en
g
the following codes are stored in the event memory:

n
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Cop py
♦ P0401 “EGR system flow rate too low” ht. rig
rig ht
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♦ P046C “Exhaust gas recirculation sender 1 implausible signal”
by lksw
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Prote AG.
In most cases, coking or carbonisation can be eliminated by per‐
forming the flushing and cleaning procedure described as follows
⇒ page 312 .
5.5.1 Initiating cleaning of exhaust gas recir‐

culation system
♦ Cooler flushing system for exhaust gas recirculation - VAS 542
007-
– Remove engine cover panel ⇒ page 7

– Open and remove clamp -1-.

Sharan 2011 ➤
– Unscrew bolts -2-, remove connecting pipe -3- to intake mani‐

fold.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Unscrew bolts -arrows-, pull out pipe union
orise -1- from intake nte
eo
manifold. auth
ra
ss c
– Fit adapter - VAS 542 007/7- -1- on opening of cylinder head.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Screw in original bolts -arrows- of connecting pipe and tighten
l purpos
by hand. Ensure that the seal on the adapter is not crimped.
nform
mercia
a
com
tion in
r
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– Unscrew bolt -3-.
agen
Prote AG.

– Unscrew nuts -4- and bolts -5-, remove bracket.

Sharan 2011 ➤
– Open clamp -1- and remove, push particulate filter to one side.
– Unscrew bolts -1- and nuts -2-.
– Remove connecting pipe -3- between exhaust manifold and
exhaust gas recirculation cooler.
AG. Volkswagen AG d
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h re
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spec
es, in part or in w
t to the co
– Release and pull off electrical connector -4- on exhaust gas
recirculation valve - N18- .
rrectness of i
Note
l purpos
For reasons of clarity, the turbocharger support is shown removed nf

ercia
in the figure. It is not necessary to remove the support.

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– Fit adapter - VAS 542 007/7- -1- on opening of exhaust gas Cop py
recirculation cooler.
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pyri by
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– Screw in original bolts -arrows- of connecting pipe and tighten by c lksw
cted agen
by hand. Ensure that the seal on the adapter is not crimped.
Prote AG.
– Join supply hose - VAS 542 007/2-2- of cleaning equipment to

adapter on exhaust gas recirculation cooler.
– Join return hose - VAS 542 007/2-3- of cleaning equipment to
adapter on cylinder head.
– Connect battery charger to vehicle battery.
– Connect terminal clamps of valve positioner - VAS 542 007/6-
to vehicle battery.
– Connect terminal clamps of pump - VAS 542 007/3- to vehicle
battery.
Prepare cooler flushing system for exhaust gas recirculation -
VAS 542 007-
– Fill canister - VAS 542 007/1- with 9 litres of warm (approx.
40°C - 50°C) tap water.
– Pour 1 litre of cleaning solution - D 600 200 A2- into the can‐
ister.
– Join suction hose - VAS 542 007/2-1- of pump to connection
-1- on canister lid.

Sharan 2011 ➤
– Insert open end of return hose - VAS 542 007/2-3- into opening
-arrow- of canister lid up to approx. half canister height.
– Fit connector of valve adjuster - VAS 542 007/6- on exhaust
gas recirculation valve - N18- .
– Switch on valve adjuster - VAS 542 007/6- to open exhaust
gas recirculation valve.
Note
♦ Ensure that the tap of the relief valve on the supply hose is
closed.
♦ If activation of the exhaust gas recirculation valve via the valve
adjuster - VAS 542sw 007/6-
agen including approx.
AG. Volkswagen AG d 1.6 bar pressure
oes
from the pumpby-VVAS 542 007/3- is not sufficient
olk not to open the
gu
exhaust gas risedrecirculation valve, the pump switches ara
noff
tee
after a
brief period.
tho In this case, the exhaust gas recirculation valve
o
au
has assmechanical defect and the exhaust gas recirculation
ra
c
valve must be renewed. Before disconnecting the supply
ce
le
un
pt
hose, carefully open the relief valve tap to release the pressure
an
d
itte
and collect the escaping cleaning solution.
y li
rm
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ility
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– While the cleaning process is running, clean the connecting
wit
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pipes ⇒ page 317 .
h re
hole
spec
– Actuate pump - VAS 542 007/3- as follows:
es, in part or in w
Pump - VAS 542 Time Scenario t to the co

007/3-
rrectness of i
Switch on 25 min. Clean

Switch off 10 min. Period for cleaning
l purpos
solution to take ef‐

fect
nform
ercia
Switch on 25 min. Clean

m
Switch off --- End of cleaning

com
tion in
process
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te o
thi
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– Disconnect intake hose from canister, switch on pump until no

do
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rp
more cleaning solution is delivered (system is emptied in doing

um
fo
so).
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– Pull out return hose from canister, pay attention to escaping
t. C rig
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cleaning solution. pyri by
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by c lksw
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– Empty canister, observe country-specific disposal regulations.
Prote AG.
– Fill canister with 10 litres of warm (approx. 40°C - 50°C) tap

water.
– Join suction hose - VAS 542 007/2-1- of pump to connection
on canister lid.
– Feed return hose - VAS 542 007/2-3- into a suitable container
(with a capacity of at least 12 litres) and secure in place.
– Switch on pump - VAS 542 007/3- until entire contents of can‐
ister have flown through exhaust gas recirculation system.
– Release and pull off supply hose - VAS 542 007/2-2- from
adapter on exhaust gas recirculation cooler.
– Connect compressed air adapter - VAS 542 007/5- to adapter
on exhaust gas recirculation cooler.
– Insert open end of return hose - VAS 542 007/2-3- into opening
-arrow- of canister lid up to approx. half canister height.

Sharan 2011 ➤
– Suction hose - VAS 542 007/2-1- of pump must be joined to

connection -1- on canister lid.
– Fit compressed air line to compressed air adapter - VAS 542
007/5- , and completely blow out remaining water from ex‐
haust gas recirculation system.
Caution
The water must be removed from the exhaust gas recirculation

system without trace. Otherwise there may be problems with
starting the engine.
– Release and pull off compressed air adapter - VAS 542

007/5- .
– Detach adapter from exhaust gas recirculation cooler.
– Pull off connector of valve adjuster - VAS 542 007/6- from ex‐
haust gas recirculation valve - N18- , fit original connector.
– Check effectiveness of cleaning with ⇒ Vehicle diagnostic
tester.
♦ Drive
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Diesel direct injection and glow plug system
EDC 17
♦ 01 - Engine electronics functions

♦ 01 - Checking exhaust gas recirculation valve 1 -
GX5- after cleaning in accordance with workshop
manual AG. Volkswagen AG d
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olksw not
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If the result of the test is »Not OK«, the exhaust gas recirculation
ed by gu
ara
cooler with integrated exhaust gas recirculation valve tho-
risN18- must nte
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be renewed ⇒ page 305 . s au ra
c
s
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le
After cleaning has been successfully conducted:

un
pt
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itte
– Install connecting pipe with new seals and new nuts

y li
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ab
⇒ page 304 .
ility
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– Bring particulate filter to installation position with new gasket

is n
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and new clamp, and secure it ⇒ page 279 .

ole,
spec

t to the co
– Release and pull off return hose on cylinder head adapter.

– Insert pipe union -1- in intake manifold. Note: opening of union
rrectne
points towards throttle valve module.

s
– Screw in bolts -arrows- and tighten to 9 Nm.

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Sharan 2011 ➤
– Remove adapter on cylinder head, install connecting pipe with

new seal ⇒ page 304 .
– Fit engine cover panel ⇒ page 7 .
– Carry out road test.
– Therefore, read event memory and erase entries if necessary.
5.5.2 Cleaning connecting pipes and pipe un‐

ion
♦ Ultrasonic cleaning device - VAS 6418-
– Close drain tap -arrow- of ultrasonic cleaning unit - VAS 6418-
at right-hand side of housing.
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The ultrasonic bath can be heated up faster by using warmisetap
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– Fill ultrasonic cleaning device - VAS 6418- with 1800 ml of tap
ce
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pt
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water and 200 ml of cleaner - D 600 200 A2- .
an
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– Insert connecting pipes and pipe union. Adjust position of con‐
ility
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necting pipes in bath where necessary.
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– Switch on cleaning unit by pressing on/off button -C-.
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– Turn rotary temperature switch -B- until lamp indicator is at 40°
t to the co
C warm-up temperature
– Set rotary switch for operating period -A- to “10” -arrow-.
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– Press and hold ► -D- for longer than 2 seconds and, in doing
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so, bring equipment into operation.
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Temperature-controlled cleaning is now activated. During the

or c
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warm-up period, ultrasonic waves are activated to mix the clean‐

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a
ing fluid. Once the preselected temperature is reached, the ultra‐

iv
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sonic waves are switched to continuous operation. Cleaning time

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must be at least 10 minutes, and cleaning only starts at a tem‐

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perature of at least 40°C. t. Cop py
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– Once cleaning is complete, flush connecting pipes and pipe
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union with clean water and blow out with compressed air. Prote AG.

Sharan 2011 ➤
28 – Glow plug system

1 Checking glow plug system
⇒ “1.1 Removing and installing glow plugs”, page 318
⇒ “1.2 Removing and installing automatic glow period control unit
J179 ”, page 320
The automatic glow period control unit - J179- is located in the
relay and fuse holder in the electronics box in the plenum cham‐
ber.
1 - Automatic glow period control unit - J179-
The glow plug system is controlled by means of an automatic glow
period control unit - J179- The automatic glow period control unit
- J179- is capable of self-diagnosis.
A fault entry is stored in the engine control unit if a fault occurs in
the glow plug system.
The procedure for checking the glow plug system is described in
“guided fault finding”.
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
1.1 Removing and installing glow plugs

♦ T-bar and socket, 10 mm - 3220-Volkswa
AG. gen AG
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♦ Pliers - 3314-
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– Switch off ignition. by c lksw
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318 Rep. gr.28 - Glow plug system

Sharan 2011 ➤
AG. Volkswagen AG d
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♦ Ensure that no line connection is damaged when
ss a discon‐
u ra
c
necting the glow plug connectors, as the entire wiring
ce
le
un
harness otherwise has to be renewed.
pt
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♦ Do not compress the pliers - 3314- too firmly to pull off the
rm
ab
pe
glow plug connectors, as the support sleeve may other‐
ility
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wise be damaged.
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– Open retaining clips -arrows- on wiring harness and pull elec‐
t to the co
trical connectors off glow plugs.
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– Position pliers - 3314- with groove -arrow A- on support sleeve
en
ng
t.
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shoulder -arrow B- and pull glow plug connectors off glow
Co
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plugs.
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– Clean glow plug channel in cylinder head; make sure no dirt
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gets into cylinder. Prote AG.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
opening, let it work in briefly and blow out with compressed air.
♦ Then clean glow plug opening using a cloth moistened with oil.
– To loosen the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- .
Installing
• Specified torque 18 Nm
1. Checking glow plug system 319

Sharan 2011 ➤
– Reattach glow plug connectors -1- to glow plugs -arrow-.
Note
olkswagen AG
en AG. V
Make sure that glow plug connectors
olks
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1.2 Removing and installing automatic glow
h re
hole
period control unit - J179-
spec
es, in part or in w
t to the co
Removing
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
rrectness of i
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nform
mercia
at
om
ion
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or
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ate
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en
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– Unscrew bolts -arrows- and remove battery mounting bracket
Co
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-1-. t. C rig
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by
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– Pull out relay holder beneath engine compartment electronics

box -arrow-.
– Pull automatic glow period control unit - J179- -item 1- from its
location in relay holder in engine compartment electronics box.
Installing
– Install battery ⇒ Electrical system; Rep. gr. 27 .
320 Rep. gr.28 - Glow plug system

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Service

Service Department. Technical Information

23 - Mixture preparation - injection

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Copyright © 2018 Volkswagen AG, Wolfsburg D3E802D67D4

1.4 Separating engine from dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.5 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.6 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.3 Poly V-belt drive without air conditioning compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.5 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.6 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.7 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.4 Assembly overview - Dual-mass flywheel and sealing flange . . . . . . . . . . . . . . . . . . . . . . 49

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.5 Removing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

2.6 Installing a new balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

2.7 Installing a previously used balancer shaft module again . . . . . . . . . . . . . . . . . . . . . . . . . . 135

3 Oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

3.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 147

1.3 Assembly overview - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

1.4 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

2 Repairing cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

5.4 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

5.5 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1.3 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

2.1 Installing hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

2.2 Installing hose connections with corrugated pipe connection . . . . . . . . . . . . . . . . . . . . . . 218

2.3 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

2.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

3.4 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

2.2 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

code”, and the second part (6 characters), the “serial number”. If

letters, the first of the six digits is replaced by a letter.

1.2 Engine data

Codes CFFA CFFB CFGB CFGC CFFE

Codes CFFA CFFB CFGB CFGC CFFE

2 Rep. gr.00 - Technical data

⇒ “2.6 Safety precautions when working on exhaust system”,

2.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.

The fuel system is pressurised. Injury from fuel spray possible.

– Wear protective gloves.

and carefully loosen the connection.

Danger of fire caused by escaping fuel

2.2 Safety measures when working on vehicles with a start/stop system

2.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant

On a warm engine, the cooling system is under high pressure.